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Full text of "Yamaha Xvs-650T V-Star (2005 Manual)"

OWNER'S MANUAL 




XVS650T(C) 
XVS650AT(C) 
VS650ATT(C) 




5FB-2819 




A WARNING 



The engine exhaust from this product 
contains chemicals known to the 
State of California to cause cancer, birth 
defects or other reproductive harm. 



YAMAHA 



L1T-CALIF-65-01 



INTRODUCTION 



Congratulations on your purchase of the Yamaha XVS650(C)/XVS650A(C)/XVS650AT(C). This model is the result of 
Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high 
degree of craftsmanship and reliability that have made Yamaha a leader in these fields. 

This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you 
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. 
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at 
the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the 
motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the 
recommended maintenance schedules and operating instructions contained within this manual. 



IMPORTANT MANUAL INFORMATION 



Particularly important information is distinguished in this manual by the following notations: 



& 


The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS 
INVOLVED! 




Failure to follow WARNING instructions could result in severe injury or death to the 
motorcycle operator, a bystander or a person inspecting or repairing the motor- 
cycle. 


1 Ak WARNING 1 




CAUTION: 


A CAUTION indicates special precautions that must be taken to avoid damage to 
the motorcycle. 


NOTE: 


A NOTE provides key information to make procedures easier or clearer. 



NOTE: 



• This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle 
is subsequently sold. 

• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most 
current product information available at the time of printing, there may be minor discrepancies between your motorcycle 
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. 



A WARNING 



PLEASE READ THIS MANUAL AND THE "YOU AND YOUR MOTORCYCLE: RIDING TIPS" BOOKLET CAREFULLY 
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTOR- 
CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES 



IMPORTANT MANUAL INFORMATION 



AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS 
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY 
THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. 



IMPORTANT MANUAL INFORMATION 



AFFIX DEALER 
LABEL HERE 



XVS650T(C)/XVS650AT(C)/XVS650ATT(C) 

OWNER'S MANUAL 

©2004 by Yamaha Motor Corporation, U.S.A. 

1st edition, April 2004 

All rights reserved. 

Any reprinting or unauthorized use 

without the written permission of 

Yamaha Motor Corporation, U.S.A. 

is expressly prohibited. 

Printed in Japan. 

P/NLIT-1 1626-1 8-20 



TABLE OF CONTENTS 



SAFETY INFORMATION 1-1 

Location of important labels 1-5 

DESCRIPTION 2-1 

Left view 2-1 

Right view 2-3 

Controls and instruments 2-5 

INSTRUMENT AND CONTROL 

FUNCTIONS 3-1 

Main switch/steering lock 3-1 

Indicator and warning lights 3-2 

Speedometer unit 3-2 

Handlebar switches 3-3 

Clutch lever 3-4 

Shift pedal (XVS650) 3-4 

Shift pedal (XVS650A/AT) 3-4 

Brake lever 3-5 

Brake pedal 3-5 

Fuel tank cap 3-5 

Fuel 3-6 

Catalytic converter 3-7 

Fuel cock 3-7 

Starter (choke) knob 3-8 

Seats (XVS650) 3-9 

Seats (XVS650A/AT) 3-10 

Helmet holder 3-1 1 

Storage compartment 3-1 1 

Adjusting the shock absorber 

assembly 3-12 

Luggage strap holders 3-13 



Sidestand 3-13 

Ignition circuit cut-off system 3-14 

PRE-OPERATION CHECKS 4-1 

Pre-operation check list 4-2 

OPERATION AND IMPORTANT 
RIDING POINTS 5-1 

Starting and warming up a 

cold engine 5-1 

Starting a warm engine 5-2 

Shifting 5-3 

Engine break-in 5-4 

Parking 5-5 

PERIODIC MAINTENANCE AND 

MINOR REPAIR 6-1 

PERIODIC MAINTENANCE 6-1 

Owner's tool kit 6-1 

Periodic maintenance chart for the 

emission control system 6-3 

General maintenance and 

lubrication chart 6-4 

Removing and installing panels 6-8 

Checking the spark plugs 6-9 

Canister (for California only) 6-10 

Engine oil and oil filter element .... 6-1 1 

Final gear oil 6-13 

Cleaning the airfilter element 6-14 

Adjusting the carburetors 6-16 



Adjusting the throttle cable 

free play 6-16 

Adjusting the valve clearance 6-16 

Tires 6-17 

Spoke wheels 6-19 

Accessories and replacement 

parts 6-19 

Adjusting the clutch lever 

free play 6-20 

Adjusting the brake lever 

free play 6-21 

Adjusting the brake pedal position 

and free play 6-22 

Adjusting the rear brake light 

switch 6-23 

Checking the front brake pads 

and rear brake shoes 6-24 

Checking the brake fluid level 6-24 

Changing the brake fluid 6-25 

Checking and lubricating the 

cables 6-25 

Checking and lubricating the 

throttle grip and cable 6-26 

Checking and lubricating the 

brake and shift pedals 6-26 

Checking and lubricating the 

brake and clutch levers 6-26 

Checking and lubricating the 

sidestand 6-27 

Checking the front fork 6-27 

Checking the steering 6-28 



TABLE OF CONTENTS 



Checking the wheel bearings 6-28 

Battery 6-29 

Replacing the fuses 6-30 

Replacing the headlight bulb 6-31 

Replacing a turn signal light bulb 

or the tail/brake light bulb 6-32 

Supporting the motorcycle 6-33 

Front wheel 6-34 

Rear wheel 6-35 

Troubleshooting 6-37 

Troubleshooting chart 6-38 

MOTORCYCLE CARE AND 

STORAGE 7-1 

Care 7-1 

Storage 7-3 

SPECIFICATIONS 8-1 

CONSUMER INFORMATION 9-1 

Identification numbers 9-1 

Reporting safety defects 9-3 

Motorcycle noise regulation 9-4 

Maintenance record 9-5 

YAMAHA MOTOR CORPORATION, 

U.S.A. STREET AND ENDURO 

MOTORCYCLE LIMITED 

WARRANTY 9-7 

YAMAHA EXTENDED SERVICE 

(Y.E.S.) 9-9 



A SAFETY INFORMATION 



MOTORCYCLES ARE SINGLE 
TRACK VEHICLES. THEIR SAFE 
USE AND OPERATION ARE DEPEN- 
DENT UPON THE USE OF PROPER 
RIDING TECHNIQUES AS WELL AS 
THE EXPERTISE OF THE OPERA- 
TOR. EVERY OPERATOR SHOULD 
KNOW THE FOLLOWING REQUIRE- 
MENTS BEFORE RIDING THIS 
MOTORCYCLE. 
HE OR SHE SHOULD: 

• OBTAIN THOROUGH INSTRUC- 
TIONS FROM A COMPETENT 
SOURCE ON ALL ASPECTS OF 
MOTORCYCLE OPERATION. 

• OBSERVE THE WARNINGS 
AND MAINTENANCE REQUIRE- 
MENTS IN THE OWNER'S MAN- 
UAL. 

• OBTAIN QUALIFIED TRAINING 
IN SAFE AND PROPER RIDING 
TECHNIQUES. 

• OBTAIN PROFESSIONAL TECH- 
NICAL SERVICE AS INDICATED 
BY THE OWNER'S MANUAL 



AND/OR WHEN MADE NECES- 
SARY BY MECHANICAL CONDI- 
TIONS. 

Safe riding 

• Always make pre-operation 
checks. Careful checks may help 
prevent an accident. 

• This motorcycle is designed to 
carry the operator and a passen- 
ger. 

• The failure of motorists to detect 
and recognize motorcycles in traf- 
fic is the predominating cause of 
automobile/motorcycle accidents. 
Many accidents have been 
caused by an automobile driver 
who did not see the motorcycle. 
Making yourself conspicuous ap- 
pears to be very effective in reduc- 
ing the chance of this type of 
accident. 

Therefore: 

• Wear a brightly colored jacket. 

• Use extra caution when ap- 
proaching and passing through 
intersections, since intersec- 



1-1 



tions are the most likely places 
for motorcycle accidents to oc- 
cur. 

• Ride where other motorists can 
see you. Avoid riding in another 
motorist's blind spot. 

• Many motorcycle accidents in- 
volve inexperienced operators. In 
fact, many operators who have 
been involved in accidents do not 
even have a current motorcycle li- 
cense. 

• Make sure that you are qualified 
and that you only lend your 
motorcycle to other qualified op- 
erators. 

• Know your skills and limits. 
Staying within your limits may 
help you to avoid an accident. 

• We recommend that you prac- 
tice riding your motorcycle 
where there is no traffic until you 
have become thoroughly famil- 
iar with the motorcycle and all of 
its controls. 

• Many motorcycle accidents have 
been caused by error of the motor- 
cycle operator. A typical error 
made by the operator is veering 



A SAFETY INFORMATION 



wide on a turn due to EXCESSIVE 
SPEED or undercomering (insuffi- 
cient lean angle for the speed). 

• Always obey the speed limit and 
never travel faster than warrant- 
ed by road and traffic conditions. 

• Always signal before turning or 
changing lanes. Make sure that 
other motorists can see you. 

The posture of the operator and 
passenger is important for proper 
control. 

• The operator should keep both 
hands on the handlebar and 
both feet on the operator foot- 
rests during operation to main- 
tain control of the motorcycle. 

• The passenger should always 
hold onto the operator, seat 
strap, or grab bar, if equipped, 
with both hands and keep both 
feet on the passenger footrests. 

• Never carry a passenger unless 
he or she can firmly place both 
feet on the passenger footrests. 

Never ride under the influence of 
alcohol or other drugs. 



• This motorcycle is designed for on- 
road use only, therefore, it is not 
suitable for off-road use. 

Protective apparel 

The majority of fatalities from motor- 
cycle accidents are the result of head 
injuries. The use of a safety helmet is 
the single most critical factor in the pre- 
vention or reduction of head injuries. 

• Always wear an approved helmet. 

• Wear a face shield or goggles. 
Wind in your unprotected eyes 
could contribute to an impairment 
of vision which could delay seeing 
a hazard. 

• The use of a jacket, heavy boots, 
trousers, gloves, etc., is effective in 
preventing or reducing abrasions 
or lacerations. 

• Never wear loose-fitting clothes, 
otherwise they could catch on the 
control levers, footrests, or wheels 
and cause injury or an accident. 

• Never touch the engine or exhaust 
system during or after operation. 
They become very hot and can 



cause burns. Always wear protec- 
tive clothing that covers your legs, 
ankles, and feet. 
• Passengers should also observe 
the precautions mentioned above. 

Modifications 

Modifications made to this motorcycle 
not approved by Yamaha, or the re- 
moval of original equipment, may ren- 
der the motorcycle unsafe for use and 
may cause severe personal injury. 
Modifications may also make your 
motorcycle illegal to use. 

Loading and accessories 

Adding accessories or cargo to your 
motorcycle can adversely affect stabili- 
ty and handling if the weight distribution 
of the motorcycle is changed. To avoid 
the possibility of an accident, use ex- 
treme caution when adding cargo or 
accessories to your motorcycle. Use 
extra care when riding a motorcycle 
that has added cargo or accessories. 
Here are some general guidelines to 
follow if loading cargo or adding acces- 
sories to your motorcycle: 



1-2 



A SAFETY INFORMATION 



Loading 

The total weight of the operator, pas- 
senger, accessories and cargo must 
not exceed the maximum load limit. 



Maximum load: 

XVS650 178 kg (392 lb) (CAL) 
XVS650 180 kg (397 lb) (U49) 
XVS650A 198 kg (437 lb) (CAL) 
XVS650A 200 kg (441 lb) (U49) 
XVS650AT 198 kg (437 lb) (CAL) 
XVS650AT 200 kg (441 lb) (U49) 



When loading within this weight limit, 
keep the following in mind: 

• Cargo and accessory weight 
should be kept as low and close to 
the motorcycle as possible. Make 
sure to distribute the weight as 
evenly as possible on both sides of 
the motorcycle to minimize imbal- 
ance or instability. 

• Shifting weights can create a sud- 
den imbalance. Make sure that ac- 
cessories and cargo are securely 
attached to the motorcycle before 
riding. Check accessory mounts 
and cargo restraints frequently. 



• Never attach any large or heavy 
items to the handlebar, front fork, 
or front fender. These items, in- 
cluding such cargo as sleeping 
bags, duffel bags, or tents, can 
create unstable handling or slow 
steering response. 

Accessories 

Genuine Yamaha accessories have 
been specifically designed for use on 
this motorcycle. Since Yamaha cannot 
test all other accessories that may be 
available, you must personally be re- 
sponsible for the proper selection, in- 
stallation and use of non-Yamaha 
accessories. Use extreme caution 
when selecting and installing any ac- 
cessories. 

Keep the following guidelines in mind, 
as well as those provided under "Load- 
ing" when mounting accessories. 

• Never install accessories or carry 
cargo that would impair the perfor- 
mance of your motorcycle. Care- 
fully inspect the accessory before 
using it to make sure that it does 
not in any way reduce ground 
clearance or cornering clearance, 



limit suspension travel, steering 
travel or control operation, or ob- 
scure lights or reflectors. 

• Accessories fitted to the handle- 
bar or the front fork area can 
create instability due to improper 
weight distribution or aerody- 
namic changes. If accessories 
are added to the handlebar or 
front fork area, they must be as 
lightweight as possible and 
should be kept to a minimum. 

• Bulky or large accessories may 
seriously affect the stability of 
the motorcycle due to aerody- 
namic effects. Wind may at- 
tempt to lift the motorcycle, or 
the motorcycle may become un- 
stable in cross winds. These ac- 
cessories may also cause 
instability when passing or being 
passed by large vehicles. 

• Certain accessories can dis- 
place the operator from his or 
her normal riding position. This 
improper position limits the free- 
dom of movement of the opera- 



1-3 



A SAFETY INFORMATION 



tor and may limit control ability, 
therefore, such accessories are 
not recommended. 

• Use caution when adding electri- 
cal accessories. If electrical acces- 
sories exceed the capacity of the 
motorcycle's electrical system, an 
electric failure could result, which 
could cause a dangerous loss of 
lights or engine power. 

Gasoline and exhaust gas 

• GASOLINE IS HIGHLY FLAMMA- 
BLE: 

• Always turn the engine off when 
refueling. 

• Take care not to spill any gaso- 
line on the engine or exhaust 
system when refueling. 

• Never refuel while smoking or in 
the vicinity of an open flame. 

• Never start the engine or let it run 
for any length of time in a closed 
area. The exhaust fumes are poi- 
sonous and may cause loss of 
consciousness and death within a 
short time. Always operate your 
motorcycle in an area that has ad- 
equate ventilation. 



• Always turn the engine off before 
leaving the motorcycle unattended 
and remove the key from the main 
switch. When parking the motor- 
cycle, note the following: 

• The engine and exhaust system 
may be hot, therefore, park the 
motorcycle in a place where pe- 
destrians or children are not like- 
ly to touch these hot areas. 

• Do not park the motorcycle on a 
slope or soft ground, otherwise it 
may fall over. 

• Do not park the motorcycle near 
a flammable source (e.g. a kero- 
sene heater, or near an open 
flame), otherwise it could catch 
fire. 

• When transporting the motorcycle 
in another vehicle, make sure that 
it is kept upright and that the fuel 
cock is turned to "ON" or "RES" (for 
vacuum type) / "OFF" (for manual 
type). If it should lean over, gaso- 
line may leak out of the carburetor 
or fuel tank. 

• If you should swallow any gaso- 
line, inhale a lot of gasoline vapor, 
or allow gasoline to get into your 

1-4 



eyes, see your doctor immediately. 
If any gasoline spills on your skin 
or clothing, immediately wash the 
affected area with soap and water 
and change your clothes. 



A SAFETY INFORMATION 



Location of important labels 

Please read the following important labels carefully before operating this vehicle. 




4,5 3 



1-5 



A SAFETY INFORMATION 



A WARNING 



• BEFORE YOU OPERATE THIS VEHICLE, READ 
THE OWNER'S MANUAL AND ALL LABELS. 

• ALWAYS WEAR AN APPROVED MOTORCYCLE 

HELMET, eye protection, and protective clothing. 



A WARNING 



This unit contains high pressure nitrogen gas. 
Mishandling can cause explosion. 

• Read owner's manual for instructions. 

• Do not incinerate, puncture or open. 



3 XVS650 



TIRE INFORMATION 



Cold tire normal pressure should be set as 
follows. 

• Up to 90 kg (198 lbs) load 

FRONT : 200 kPa, {2.00 kgf/cm 2 }, 29 psi 
REAR : 225 kPa, {2.25 kgf/cm 2 }, 33 psi 

• 90 kg (198 lbs) ~ maximum load 
FRONT : 200 kPa, {2.00 kgf/cm 2 }, 29 psi 
REAR : 250 kPa, {2.50 kgf/cm 2 }, 36 psi 



5FB-21668-00 



3 XVS650A/AT 



TIRE INFORMATION 


Cold tire normal pressure should be set as 


follows. 








• Up to 90 kg (198 lbs) load 




FRONT 


: 225 kPa 


{2.25 kgf/cm 2 }, 


33 psi 


REAR 


: 225 kPa 


{2.25 kgf/cm 2 >, 


33 psi 


• 90 kg (198 lbs) ~ 


naximum load 




FRONT 


: 225 kPa 


{2.25 kgf/cm 2 >, 


33 psi 


REAR 


: 250 kPa 


{2.50 kgf/cm 2 }, 


36 psi 



5BN-2 1668-00 



LOAD LIMIT 



1 Kg {2 lbs} 



4BR-24877-A0 J 



1-6 



A SAFETY INFORMATION 





A WARNING 


Improper loading can cause loss of control. 
Read owner's manual for proper loading. 


3JJ-28446-A1 



6 California only 



EMISSION HOSE ROUTING 



CARB CARB 




FROM 
FUEL TANK 



ROLL OVER VALVE A 



r 



CANISTER 
TO ATMOSPHERE 



5BN-21686-00 



1-7 



DESCRIPTION 



Left view 

XVS650 




1 . Shift pedal (page 3-4) 

2. Fuel cock (page 3-7) 

3. Starter (choke) knob (page 3-8) 

4. Shock absorber assembly spring preload adjusting ring (page 3-12) 

5. Helmet holder (page 3-11) 

6. Owner's tool kit (page 6-1) 



7. Storage compartment (page 3-11) 



2-1 



DESCRIPTION 



XVS650A/AT 




1 . Shift pedal (page 3-4) 

2. Fuel cock (page 3-7) 

3. Starter (choke) knob (page 3-8) 

4. Shock absorber assembly spring preload adjusting ring (page 3-12) 

5. Helmet holder (page 3-11) 

6. Owner's tool kit (page 6-1) 

7. Storage compartment (page 3-11) 



2-2 



DESCRIPTION 



Right view 

XVS650 




1 . Engine oil filter element (page 6-11) 

2. Battery (page 6-29) 

3. Fuses (page 6-30) 

4. Main switch/steering lock (page 3-1) 

5. Air filter element (page 6-14) 

6. Brake pedal (page 3-5) 



2-3 



DESCRIPTION 



XVS650A/AT 




1 . Engine oil filter element (page 6-1 1 ) 

2. Battery (page 6-29) 

3. Fuses (page 6-30) 

4. Main switch/steering lock (page 3-1) 

5. Air filter element (page 6-1 4) 

6. Brake pedal (page 3-5) 



2-4 



DESCRIPTION 



Controls and instruments 




1 . Clutch lever (page 3-4) 

2. Left handlebar switches (page 3-3) 

3. Speedometer unit (page 3-2) 

4. Fuel tank cap (page 3-5) 

5. Right handlebar switches (page 3-3) 

6. Throttle grip (page 6-16) 

7. Brake lever (page 3-5) 



2-5 



INSTRUMENT AND CONTROL FUNCTIONS 



Main switch/steering lock 




LOOK* 



The main switch/steering lock controls 
the ignition and lighting systems, and is 
used to lock the steering. The various 
positions are described below. 

EAU10510 

ON 

All electrical systems are supplied with 
power, and the headlight, meter light- 
ing, taillight and position lights come 
on, and the engine can be started. The 
key cannot be removed. 

EAU10660 

OFF 

All electrical systems are off. The key 
can be removed. 



LOCK 

The steering is locked, and all electrical 
systems are off. The key can be re- 
moved. 

To lock the steering 




Push. 
Turn. 



Turn the handlebars all the way to 
the left. 

Push the key in from the "OFF" po- 
sition, and then turn it to "LOCK" 
while still pushing it. 
Remove the key. 



To unlock the steering 
1 2 




1. Push. 

2. Turn. 



Push the key in, and then turn it to 
"OFF" while still pushing it. 



A WARNING 



Never turn the key to "OFF" or 
"LOCK" while the vehicle is moving, 
otherwise the electrical systems will 
be switched off, which may result in 
loss of control or an accident. Make 
sure that the vehicle is stopped be- 
fore turning the key to "OFF" or 
"LOCK". 



3-1 



INSTRUMENT AND CONTROL FUNCTIONS 



Indicator and warning lights 




1 . High beam indicator light " 10" 

2. Turn signal indicator light "<£ c>" 

3. Neutral indicator light " N " 

4. Engine trouble warning light " hS " 



Turn signal indicator light "<? ^>" 

This indicator light flashes when the 
turn signal switch is pushed to the left or 
right. 

EAU 11060 

Neutral indicator light " N " 

This indicator light comes on when the 
transmission is in the neutral position. 



High beam indicator light "id" 

This indicator light comes on when the 
high beam of the headlight is switched 
on. 

EAU 11500 

Engine trouble warning light " hS " 
This warning light comes on or flashes 
when an electrical circuit monitoring the 
engine is defective. When this occurs, 
have a Yamaha dealer check the self- 
diagnosis system. 

The electrical circuit of the warning light 
can be checked by turning the key to 
"ON". If the warning light does not come 
on for a few seconds, then go off, have 
a Yamaha dealer check the electrical 
circuit. 



Speedometer unit 




1. Tripmeter reset knob 

2. Speedometer 

3. Odometer 

4. Tripmeter 

The speedometer unit is equipped with 
a speedometer, an odometer and a 
tripmeter. The speedometer shows 
riding speed. The odometer shows the 
total distance traveled. The tripmeter 
shows the distance traveled since it 
was last set to zero with the reset knob. 
The tripmeter can be used to estimate 
the distance that can be traveled with a 
full tank of fuel. This information will en- 
able you to plan future fuel stops. 



3-2 



INSTRUMENT AND CONTROL FUNCTIONS 



Handlebar switches 

Left 




1. Dimmer switch "10/ 10" 

2. Turn signal switch "<>/:£>" 

3. Horn switch " ^- " 



Right 




1. Engine stop switch "(")/ £ 

2. Start switch"®" 



Dimmer switch " 10/ 10 " 

Set this switch to "10" for the high 

beam and to "10" for the low beam. 

EAU12430 

Turn signal switch "<3/c>" 
To signal a right-hand turn, push this 
switch to "=>". To signal a left-hand 
turn, push this switch to "<a". When re- 
leased, the switch returns to the center 
position. 

Since this model is equipped with a 
self-canceling system, the turn signal 
lights will self-cancel after the vehicle 
has traveled both about 150 m (490 ft) 
and for approximately 15 seconds. 
However, the turn signal lights can also 
be canceled manually by pushing the 
switch in after it has returned to the cen- 
ter position. 

NOTE: 

The self-canceling system only oper- 
ates when the vehicle is moving, so that 
the turn signal lights will not self-cancel 
while you are stopped at an intersec- 
tion. 



Horn switch " ►o- " 

Press this switch to sound the horn. 



Engine stop switch "Q/^j" 
Set this switch to "O" before starting 
the engine. Set this switch to "53" to 
stop the engine in case of an emergen- 
cy, such as when the vehicle overturns 
or when the throttle cable is stuck. 



Start switch "©" 

Push this switch to crank the engine 
with the starter. 

ECA10050 

CAUTION: 



See page 5-1 for starting instruc- 
tions prior to starting the engine. 



3-3 



INSTRUMENT AND CONTROL FUNCTIONS 



Clutch lever 



Shift pedal (XVS650) 



Shift pedal (XVS650A/AT) 




1. Clutch lever 

The clutch lever is located at the left 
handlebar grip. To disengage the 
clutch, pull the lever toward the handle- 
bar grip. To engage the clutch, release 
the lever. The lever should be pulled 
rapidly and released slowly for smooth 
clutch operation. 

The clutch lever is equipped with a 
clutch switch, which is part of the igni- 
tion circuit cut-off system. (See page 
3-14.) 



1 . Shift pedal 

The shift pedal is located on the left 
side of the engine and is used in com- 
bination with the clutch lever when 
shifting the gears of the 5-speed con- 
stant-mesh transmission equipped on 
this motorcycle. 




1 . Shift pedal 

The shift pedal is located on the left 
side of the engine and is used in com- 
bination with the clutch lever when 
shifting the gears of the 5-speed con- 
stant-mesh transmission equipped on 
this motorcycle. 

NOTE: 

Use your toes or heel to shift up and 
your toes to shift down. 



3-4 



INSTRUMENT AND CONTROL FUNCTIONS 



Brake lever 




1 . Brake lever 

The brake lever is located at the right 
handlebar grip. To apply the front 
brake, pull the lever toward the handle- 
bar grip. 



Brake pedal 

XVS650 



Fuel tank cap 




1 . Brake pedal 
XVS650A/AT 




1 . Brake pedal 

The brake pedal is on the right side of 
the motorcycle. To apply the rear 
brake, press down on the brake pedal. 





To remove the fuel tank cap 

Slide the lock cover open, insert the key 
into the lock, and then turn it 1/4 turn 
clockwise. The lock will be released 
and the fuel tank cap can be removed. 

To install the fuel tank cap 

1. Insert the fuel tank cap into the 
tank opening with the key inserted 
in the lock and with the "A" mark 
facing forward. 

2. Turn the key counterclockwise to 
the original position, remove it, and 
then close the lock cover. 



3-5 



INSTRUMENT AND CONTROL FUNCTIONS 



NOTE: 

The fuel tank cap cannot be installed 
unless the key is in the lock. In addition, 
the key cannot be removed if the cap is 
not properly installed and locked. 



A WARNING 



Fuel 



CAUTION: 



Make sure that the fuel tank cap is 
properly installed before riding. 




1. Fuel tank filler tube 

2. Fuel level 

Make sure that there is sufficient fuel in 
the tank. Fill the fuel tank to the bottom 
of the filler tube as shown. 



A WARNING 



Do not overfill the fuel tank, oth- 
erwise it may overflow when the 
fuel warms up and expands. 
Avoid spilling fuel on the hot en- 
gine. 



Immediately wipe off spilled fuel 
with a clean, dry, soft cloth, since 
fuel may deteriorate painted surfac- 
es or plastic parts. 



Recommended fuel: 

UNLEADED GASOLINE ONLY 
Fuel tank capacity: 

16.0 L (4.23 US gal) (3.52 Imp.gal) 
Fuel reserve amount: 

3.0 L (0.79 US gal) (0.66 Imp.gal) 



CAUTION: 



Use only unleaded gasoline. The use 
of leaded gasoline will cause severe 
damage to internal engine parts, 
such as the valves and piston rings, 
as well as to the exhaust system. 

Your Yamaha engine has been de- 
signed to use regular unleaded gaso- 
line with a pump octane number 
[(R+M)/2] of 86 or higher, or a research 
octane number of 91 or higher. If 



3-6 



INSTRUMENT AND CONTROL FUNCTIONS 



knocking (or pinging) occurs, use a 
gasoline of a different brand or premi- 
um unleaded fuel. Use of unleaded fuel 
will extend spark plug life and reduce 
maintenance costs. 
Gasohol 

There are two types of gasohol: gaso- 
hol containing ethanol and that contain- 
ing methanol. Gasohol containing 
ethanol can be used if the ethanol con- 
tent does not exceed 10%. Gasohol 
containing methanol is not recom- 
mended by Yamaha because it can 
cause damage to the fuel system or ve- 
hicle performance problems. 



Catalytic converter 

This vehicle is equipped with a catalytic 
converter in the muffler. 



A WARNING 



The exhaust system is hot after op- 
eration. Make sure that the exhaust 
system has cooled down before do- 
ing any maintenance work. 

ECA10700 

CAUTION: 



The following precautions must be 
observed to prevent a fire hazard or 
other damages. 

• Use only unleaded gasoline. 
The use of leaded gasoline will 
cause unrepairable damage to 
the catalytic converter. 

• Never park the vehicle near pos- 
sible fire hazards such as grass 
or other materials that easily 
burn. 

• Do not allow the engine to idle 
too long. 



Fuel cock 

The fuel cock supplies fuel from the 
tank to the carburetors while also filter- 
ing it. 

The fuel cock lever positions are ex- 
plained as follows and shown in the il- 
lustrations. 

OFF 




Arrow mark positioned over "OFF" 



With the fuel cock lever in this position, 
fuel will not flow. Always turn the fuel 
cock lever to this position when the en- 
gine is not running. 



3-7 



INSTRUMENT AND CONTROL FUNCTIONS 



ON 




This indicates reserve. With the fuel 
cock lever in this position, the fuel re- 
serve is made available. Turn the fuel 
cock lever to this position if you run out 
of fuel while riding. When this occurs, 
refuel as soon as possible and be sure 
to turn the fuel cock lever back to "ON"! 



Starter (choke) knob " h 



Arrow mark positioned over "ON" 



With the fuel cock lever in this position, 
fuel flows to the carburetors. Turn the 
fuel cock lever to this position when 
starting the engine and riding. 

RES 





1 . Arrow mark positioned over "RES" 



1 . Starter (choke) knob " |\| " 

Starting a cold engine requires a richer 

air-fuel mixture, which is supplied by 

the starter (choke). 

Move the knob in direction (a) to turn on 

the starter (choke). 

Move the knob in direction (b) to turn off 

the starter (choke). 

ECA10990 

CAUTION: 

Do not use the starter (choke) for 
more than 3 minutes as the exhaust 
pipe may discolor from excessive 
heat. In addition, extended use of 
the starter (choke) will cause after- 
burning. If this occurs, turn off the 
starter (choke). 



3-8 



INSTRUMENT AND CONTROL FUNCTIONS 



Seats (XVS650) 

Passenger seat 

To remove the passenger seat 
Remove the nut, and then pull the pas- 
senger seat up. 




To install the passenger seat 
Insert the projection on the front of the 
passenger seat into the seat holder as 
shown, place the seat in the original po- 
sition, and then install the nut. 




1. Bolt 

2. Seat holder 

3. Projection 

Rider seat 

To remove the rider seat 

1 . Remove the passenger seat. 

2. Remove the bolts, and then pull 
the seat up. 




1. Seat holder 

2. Projection 

To install the rider seat 

1 . Insert the projection on the front of 
the rider seat into the seat holder 
as shown, place the seat in the 
original position, and then install 
the bolts. 

2. Install the passenger seat. 

NOTE: 

Make sure that the seats are properly 
secured before riding. 



3-9 



INSTRUMENT AND CONTROL FUNCTIONS 



Seats (XVS650A/AT) 

Passenger seat 

To remove the passenger seat 
Remove the bolt, and then pull the pas- 
senger seat up. 




Bolt 



To install the passenger seat 
Insert the projections on the front of the 
passenger seat into the holders as 
shown, place the seat in the original po- 
sition, and then install the bolt. 



To install the rider seat 

Insert the projection on the front of 
the rider seat into the holder as 
shown, place the seat in the origi- 
nal position, and then install the 
bolt. 




1 . Remove the passenger seat. 

2. Remove the bolt, and then pull the 
rider seat up. 







\ 




^ 




ylS 


M 






M k 


"\ 






1 . \ 


S. ^Itij^: 


■■MS* 



1. Seat holder 

2. Projection 

2. Install the passenger seat. 
NOTE: 



Make sure that the seats are properly 
secured before riding. 



1. Bolt 



3-10 



INSTRUMENT AND CONTROL FUNCTIONS 



Helmet holder 




1. Helmet holder 

2. Unlock. 

To open the helmet holder, insert the 

key into the lock, and then turn the key 

as shown. 

To lock the helmet holder, place it in the 

original position, and then remove the 

key. 



A WARNING 



Never ride with a helmet attached to 
the helmet holder, since the helmet 
may hit objects, causing loss of con- 
trol and possibly an accident. 



Storage compartment 

The storage compartment is located on 
the left side of the vehicle. 

To open the storage compartment 

1. Slide the lock cover open, insert 
the key into the lock, and then turn 
it clockwise. 




To close the storage compartment 

1. Place the storage compartment 
cover in its original position as 
shown. 




1 . Storage compartment cover 

2. Storage compartment lock cover 

3. Storage compartment lock 

Pull the storage compartment cov 
er out as shown. 



1. Storage compartment 

2. Storage compartment cover 

2. Turn the key counterclockwise, re- 
move it, and then close the lock 
cover. 



3-11 



INSTRUMENT AND CONTROL FUNCTIONS 



Adjusting the shock absorber 
assembly 




1. Position indicator 

2. Spring preload adjusting ring 

3. Extension bar 

4. Special wrench 

This shock absorber assembly is 
equipped with a spring preload adjust- 
ing ring. 

ECA10100 

CAUTION: 



Never attempt to turn an adjusting 
mechanism beyond the maximum or 
minimum settings. 

Adjust the spring preload as follows. 
1. Remove the passenger and rider 
seats. (See page 3-9.) 



2. To increase the spring preload and 
thereby harden the suspension, 
turn the adjusting ring in direction 
(a). To decrease the spring pre- 
load and thereby soften the sus- 
pension, turn the adjusting ring in 
direction (b). 

NOTE: 

• Align the appropriate notch in the 
adjusting ring with the position in- 
dicator on the shock absorber. 

• Use the special wrench and exten- 
sion bar included in the owner's 
tool kit to make the adjustment. 



Spring preload setting: 

Minimum (soft): 

1 
Standard: 

3 
Maximum (hard): 

7 



3. Install the passenger and rider 
seats. 



A WARNING 



This shock absorber contains highly 
pressurized nitrogen gas. For prop- 
er handling, read and understand 
the following information before 
handling the shock absorber. The 
manufacturer cannot be held re- 
sponsible for property damage or 
personal injury that may result from 
improper handling. 

• Do not tamper with or attempt to 
open the gas cylinder. 

• Do not subject the shock ab- 
sorber to an open flame or other 
high heat sources, otherwise it 
may explode due to excessive 
gas pressure. 

• Do not deform or damage the 
gas cylinder in any way, as this 
will result in poor damping per- 
formance. 

• Always have a Yamaha dealer 
service the shock absorber. 



3-12 



INSTRUMENT AND CONTROL FUNCTIONS 



Luggage strap holders 

J 




Luggage strap holder 



There is a luggage strap holder on each 
passenger footrest. 



Sidestand 

The sidestand is located on the left side 
of the frame. Raise the sidestand or 
lower it with your foot while holding the 
vehicle upright. 

NOTE: 

The built-in sidestand switch is part of 
the ignition circuit cut-off system, which 
cuts the ignition in certain situations. 
(See further down for an explanation of 
the ignition circuit cut-off system.) 



A WARNING 



The vehicle must not be ridden with 
the sidestand down, or if the side- 
stand cannot be properly moved up 
(or does not stay up), otherwise the 
sidestand could contact the ground 
and distract the operator, resulting 
in a possible loss of control. 
Yamaha's ignition circuit cut-off 
system has been designed to assist 
the operator in fulfilling the respon- 
sibility of raising the sidestand be- 
fore starting off. Therefore, check 
this system regularly as described 



below and have a Yamaha dealer re- 
pair it if it does not function proper- 
ly- 



3-13 



INSTRUMENT AND CONTROL FUNCTIONS 



Ignition circuit cut-off system 

The ignition circuit cut-off system (com- 
prising the sidestand switch, clutch 
switch and neutral switch) has the fol- 
lowing functions. 

• It prevents starting when the trans- 
mission is in gear and the side- 
stand is up, but the clutch lever is 
not pulled. 

• It prevents starting when the trans- 
mission is in gear and the clutch le- 
ver is pulled, but the sidestand is 
still down. 

• It cuts the running engine when the 
transmission is in gear and the sid- 
estand is moved down. 

Periodically check the operation of the 
ignition circuit cut-off system according 
to the following procedure. 



A WARNING 



If a malfunction is noted, have a 
Yamaha dealer check the system be- 
fore riding. 



3-14 



INSTRUMENT AND CONTROL FUNCTIONS 



With the engine turned off: 

1 . Move the sidestand down. 

2. Make sure that the engine stop switch is turned on. 

3. Turn the key on. 

4. Shift the transmission into the neutral position. 

5. Push the start switch. 
Does the engine start? 



YES 



NO 



With the engine still running: 

6. Move the sidestand up. 

7. Keep the clutch lever pulled. 

8. Shift the transmission into gear. 

9. Move the sidestand down. 
Does the engine stall? 



YES 



NO 



After the engine has stalled: 

10. Move the sidestand up. 

1 1 . Keep the clutch lever pulled. 

12. Push the start switch. 
Does the engine start? 



YES 



NO 



The system is OK. The motorcycle can be ridden. 



NOTE: 

This check is most reliable if performed with 
a warmed-up engine. 



The neutral switch may be defective. 

The motorcycle should not be ridden until 

checked by a Yamaha dealer. 



The sidestand switch may be defective. 
The motorcycle should not be ridden until 
checked by a Yamaha dealer. 



The clutch switch may be defective. 

The motorcycle should not be ridden until 

checked by a Yamaha dealer. 



3-15 



PRE-OPERATION CHECKS 



The condition of a vehicle is the owner's responsibility. Vital components can start to deteriorate quickly and unexpectedly, 
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss 
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec- 
tion, to check the following points before each ride. 

NOTE: 

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short 
time; and the added safety it assures is more than worth the time involved. 



A WARNING 



If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating 
the vehicle. 



4-1 



PRE-OPERATION CHECKS 



Pre-operation check list 



ITEM 


CHECKS 


PAGE 


Fuel 


• Check fuel level in fuel tank. 

• Refuel if necessary. 

• Check fuel line for leakage. 


3-6 


Engine oil 


• Check oil level in engine. 

• If necessary, add recommended oil to specified level. 

• Check vehicle for oil leakage. 


6-11 


Final gear oil 


• Check vehicle for oil leakage. 


6-13 


Front brake 


• Check operation. 

• If soft or spongy, have Yamaha dealer bleed hydraulic system. 

• Check lever free play. 

• Adjust if necessary. 

• Check brake pads for wear. 

• Replace if necessary. 

• Check fluid level in reservoir. 

• If necessary, add recommended brake fluid to specified level. 

• Check hydraulic system for leakage. 


6-21,6-24,6-24 


Rear brake 


• Check operation. 

• Check pedal free play. 

• Adjust if necessary. 


6-22, 6-24 


Clutch 


• Check operation. 

• Lubricate cable if necessary. 

• Check lever free play. 

• Adjust if necessary. 


6-20 


Throttle grip 


• Make sure that operation is smooth. 

• Check cable free play. 

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and 
grip housing. 


6-16,6-26 


Control cables 


• Make sure that operation is smooth. 

• Lubricate if necessary. 


6-25 



4-2 



PRE-OPERATION CHECKS 



ITEM 


CHECKS 


PAGE 


Wheels and tires 


• Check for damage. 

• Check tire condition and tread depth. 

• Check air pressure. 

• Correct if necessary. 


6-17,6-19 


Brake and shift pedals 


• Make sure that operation is smooth. 

• Lubricate pedal pivoting points if necessary. 


6-26 


Brake and clutch levers 


• Make sure that operation is smooth. 

• Lubricate lever pivoting points if necessary. 


6-26 


Sidestand 


• Make sure that operation is smooth. 

• Lubricate pivot if necessary. 


6-27 


Chassis fasteners 


• Make sure that all nuts, bolts and screws are properly tightened. 

• Tighten if necessary. 


— 


Instruments, lights, signals 
and switches 


• Check operation. 

• Correct if necessary. 


— 


Sidestand switch 


• Check operation of ignition circuit cut-off system. 

• If system is defective, have Yamaha dealer check vehicle. 


3-13 



4-3 



OPERATION AND IMPORTANT RIDING POINTS 



A WARNING 



• Become thoroughly familiar 
with all operating controls and 
their functions before riding. 
Consult a Yamaha dealer re- 
garding any control or function 
that you do not thoroughly un- 
derstand. 

• Never start the engine or oper- 
ate it in a closed area for any 
length of time. Exhaust fumes 
are poisonous, and inhaling 
them can cause loss of con- 
sciousness and death within a 
short time. Always make sure 
that there is adequate ventila- 
tion. 

• Before starting out, make sure 
that the sidestand is up. If the 
sidestand is not raised com- 
pletely, it could contact the 
ground and distract the opera- 
tor, resulting in a possible loss 
of control. 



Starting and warming up a 
cold engine 

In order for the ignition circuit cut-off 
system to enable starting, one of the 
following conditions must be met: 

• The transmission is in the neutral 
position. 

• The transmission is in gear with 
the clutch lever pulled and the sid- 
estand up. 



A WARNING 



• Before starting the engine, 
check the function of the igni- 
tion circuit cut-off system ac- 
cording to the procedure 
described on page 3-14. 

• Never ride with the sidestand 
down. 

1 . Turn the fuel cock lever to "ON". 

2. Turn the key to "ON" and make 
sure that the engine stop switch is 
set to" o". 

3. Shift the transmission into the neu- 
tral position. 



NOTE: 

When the transmission is in the neutral 
position, the neutral indicator light 
should be on, otherwise have a 
Yamaha dealer check the electrical cir- 
cuit. 

4. Turn the starter (choke) on and 
completely close the throttle. (See 
page 3-8.) 

5. Start the engine by pushing the 
start switch. 

NOTE: 

If the engine fails to start, release the 
start switch, wait a few seconds, and 
then try again. Each starting attempt 
should be as short as possible to pre- 
serve the battery. Do not crank the en- 
gine more than 10 seconds on any one 
attempt. 

ECA11370 

CAUTION: 



The engine trouble warning light 
should come on when the key is 
turned to "ON", and then go off after 
a few seconds. If the engine trouble 
warning light comes on or flashes 



5-1 



OPERATION AND IMPORTANT RIDING POINTS 



after starting, immediately stop the 
engine, and have a Yamaha dealer 
check the self-diagnosis system. 

6. After starting the engine, move the 
starter (choke) back halfway. 

ECA11130 

CAUTION: 

For maximum engine life, always 
warm the engine up before starting 
off. Never accelerate hard when the 
engine is cold! 

7. When the engine is warm, turn the 
starter (choke) off. 

NOTE: 

The engine is warm when it responds 
normally to the throttle with the starter 
(choke) turned off. To avoid the possi- 
bility of excessive exhaust emissions, 
never leave the starter (choke) on long- 
er than necessary. The time necessary 
for starter (choke) use depends upon 
the ambient temperature. Tempera- 
tures above 10 °C (50 °F) require about 
7 seconds of starter (choke) use and 
temperatures below 10 °C (50 °F) re- 
quire about 35 seconds with the starter 



(choke) turned on, then about 2.5 min- 
utes with the starter (choke) in the half- 
way position. 



Starting a warm engine 

Follow the same procedure as for start- 
ing a cold engine with the exception 
that the starter (choke) is not required 
when the engine is warm. 



5-2 



OPERATION AND IMPORTANT RIDING POINTS 



Shifting 

XVS650 




1 . Shift pedal 

2. Neutral position 

XVS650A/AT 
5 




Shifting gears lets you control the 
amount of engine power available for 
starting off, accelerating, climbing hills, 
etc. 

The gear positions are shown in the il- 
lustration. 

NOTE: 

To shift the transmission into the neu- 
tral position, press the shift pedal down 
repeatedly until it reaches the end of its 
travel, and then slightly raise it. 

ECA10260 

CAUTION: 



1 . Shift pedal 

2. Neutral position 



Even with the transmission in 
the neutral position, do not 
coast for long periods of time 
with the engine off, and do not 
tow the motorcycle for long dis- 
tances. The transmission is 
properly lubricated only when 
the engine is running. Inade- 
quate lubrication may damage 
the transmission. 
Always use the clutch while 
changing gears to avoid damag- 
ing the engine, transmission, 



and drive train, which are not 
designed to withstand the 
shock of forced shifting. 



To start out and accelerate 

1 . Pull the clutch lever to disengage 
the clutch. 

2. Shift the transmission into first 
gear. The neutral indicator light 
should go out. 

3. Open the throttle gradually, and at 
the same time, release the clutch 
lever slowly. 

4. At the recommended shift points 
shown in the following table, close 
the throttle, and at the same time, 
quickly pull the clutch lever in. 

5. Shift the transmission into second 
gear. (Make sure not to shift the 
transmission into the neutral posi- 
tion.) 

6. Open the throttle part way and 
gradually release the clutch lever. 

7. Follow the same procedure when 
shifting to the next higher gear. 



5-3 



OPERATION AND IMPORTANT RIDING POINTS 



NOTE: 

Always shift gears at the recommended 
shift points. 



To decelerate 

1. Apply both the front and the rear 
brakes to slow the motorcycle. 

2. Shift the transmission into first 
gear when the motorcycle reaches 
25 km/h (15.5 mi/h). If the engine is 
about to stall or runs very roughly, 
pull the clutch lever in and use the 
brakes to stop the motorcycle. 

3. Shift the transmission into the neu- 
tral position when the motorcycle 
is almost completely stopped. The 
neutral indicator light should come 
on. 

EAU 16720 

Recommended shift points 

The recommended shift points during 
acceleration and deceleration are 
shown in the table below. 



Shift u 


p points: 




1st - 


^2nd 


16 km/h (9.9 mi/h) 


2nd 


^3rd 


: 24 km/h (14.9 


mi/h) 


3rd 


^4th: 


32 km/h (19.9 


mi/h) 


4th- 


^ 5th: 


40 km/h (24.9 


-rii/h) 


Shift down points: 




5th - 


^4th: 


25 km/h (15.5 


-ni/h) 


4th- 


^3rd: 


25 km/h (15.5 


mi/h) 


3rd 


^2nd 


: 25 km/h (15.5 


mi/h) 


2nd 


-> 1st 


25 km/h (15.5 


mi/h) 



Engine break-in 

There is never a more important period 
in the life of your engine than the period 
between and 1600 km (1000 mi). For 
this reason, you should read the follow- 
ing material carefully. 
Since the engine is brand new, do not 
put an excessive load on it for the first 
1 600 km (1 000 mi). The various parts in 
the engine wear and polish themselves 
to the correct operating clearances. 
During this period, prolonged full-throt- 
tle operation or any condition that might 
result in engine overheating must be 
avoided. 



0-1000 km (0-600 mi) 

Avoid prolonged operation above 1/3 

throttle. 

1000-1600 km (600-1000 mi) 

Avoid prolonged operation above 1/2 
throttle. 



5-4 



OPERATION AND IMPORTANT RIDING POINTS 



CAUTION: 



After 1000 km (600 mi) of operation, 
the engine oil and final gear oil must 
be changed, and the oil filter car- 
tridge or element replaced. 

1600 km (1000 mi) and beyond 

The vehicle can now be operated nor- 
mally. 

ECA10270 

CAUTION: 

If any engine trouble should occur 
during the engine break-in period, 
immediately have a Yamaha dealer 
check the vehicle. 



Parking 

When parking, stop the engine, remove 
the key from the main switch, and then 
turn the fuel cock lever to "OFF". 



A WARNING 



• Since the engine and exhaust 
system can become very hot, 
park in a place where pedestri- 
ans or children are not likely to 
touch them. 

• Do not park on a slope or on soft 
ground, otherwise the vehicle 
may overturn. 

ECA10380 

CAUTION: 



Never park in an area where there 
are fire hazards such as grass or 
other flammable materials. 



5-5 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Safety is an obligation of the owner. Pe- 
riodic inspection, adjustment and lubri- 
cation will keep your vehicle in the 
safest and most efficient condition pos- 
sible. The most important points of 
motorcycle inspection, adjustment, and 
lubrication are explained on the follow- 
ing pages. 

Maintenance, replacement, or repair 
of the emission control devices and 
systems may be performed by any 
repair establishment or individual 
that is certified (if applicable). 



A WARNING 



If you are not familiar with mainte- 
nance work, have a Yamaha dealer 
do it for you. 



PERIODIC MAINTENANCE 

PROPER PERIODIC MAINTENANCE 
OF YOUR VEHICLE IS IMPORTANT 
IN ORDER TO ENJOY LONG, PLEA- 
SURABLE SERVICE. ESPECIALLY 
IMPORTANT ARE THE MAINTE- 
NANCE SERVICES RELATED TO 
EMISSIONS CONTROL. THESE 
CONTROLS NOT ONLY FUNCTION 
TO ENSURE CLEANER AIR, BUT 
ARE ALSO VITAL TO PROPER EN- 
GINE OPERATION AND MAXIMUM 
PERFORMANCE. IN THE FOLLOW- 
ING PERIODIC MAINTENANCE 
CHARTS, THE SERVICES RELATED 
TO EMISSIONS CONTROL ARE 
GROUPED SEPARATELY. THESE 
SERVICES REQUIRE SPECIALIZED 
DATA, KNOWLEDGE, AND EQUIP- 
MENT. YAMAHA DEALERS ARE 
TRAINED AND EQUIPPED TO PER- 
FORM THESE PARTICULAR SER- 
VICES. 



Owner's tool kit 




1 . Owner's tool kit 

The owner's tool kit is located inside the 
storage compartment. (See page 
3-11.) 

The service information included in this 
manual and the tools provided in the 
owner's tool kit are intended to assist 
you in the performance of preventive 
maintenance and minor repairs. How- 
ever, additional tools such as a torque 
wrench may be necessary to perform 
certain maintenance work correctly. 

NOTE: 

If you do not have the tools or experi- 
ence required for a particular job, have 
a Yamaha dealer perform it for you. 



6-1 



PERIODIC MAINTENANCE AND MINOR REPAIR 



A WARNING 



Modifications not approved by 
Yamaha may cause loss of perfor- 
mance, excessive emissions, and 
render the vehicle unsafe for use. 
Consult a Yamaha dealer before at- 
tempting any changes. 



6-2 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Periodic maintenance chart for the emission contro 


system 










No. 


ITEM 


ROUTINE 


INITIAL 


ODOMETER READINGS 


600 mi 
(1000 km) 

or 
1 month 


4000 mi 
(7000 km) 

or 
6 months 


8000 mi 
(13000 km) 

or 
12 months 


12000 mi 
(19000 km) 

or 
18 months 


16000 mi 
(25000 km) 

or 
24 months 


20000 mi 
(31000 km) 

or 
30 months 


1 


* 


Fuel line 


• Check fuel hoses for cracks or 
damage. 

• Replace if necessary. 




V 


V 


V 


V 


V 


2 


* 


Fuel filter 


• Replace. 












Replace. 


3 




Spark plugs 


• Check condition. 

• Adjust gap and clean. 

• Replace every 8000 mi (13000 
km) or 12 months. 




V 


Replace. 


V 


Replace. 


V 


4 


* 


Valve clearance 


• Check and adjust valve clearance 
when engine is cold. 


V 


V 


V 


V 


V 


V 


5 


* 


Crankcase breather 
system 


• Check breather hose for cracks or 
damage. 

• Replace if necessary. 




V 


V 


V 


V 


V 


6 


* 


Carburetor synchro- 
nization 


• Adjust synchronization of carbu- 
retors. 


V 


V 


V 


V 


V 


V 


7 


* 


Idle speed 


• Check and adjust engine idle 
speed. 




V 


V 


V 


V 


V 


8 


* 


Exhaust system 


• Check for leakage. 

• Tighten if necessary. 

• Replace gasket(s) if necessary. 




V 


V 


V 


V 


V 


9 


* 


Evaporative emis- 
sion control system 
(For California only) 


• Check control system for dam- 
age. 

• Replace if necessary. 








V 




V 



* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 

6-3 



PERIODIC MAINTENANCE AND MINOR REPAIR 



General maintenance and lubrication chart 







ITEM 


ROUTINE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 
(1000 km) 

or 
1 month 


4000 mi 
(7000 km) 

or 
6 months 


8000 mi 
(13000 km) 

or 
12 months 


12000 mi 
(19000 km) 

or 
18 months 


16000 mi 
(25000 km) 

or 
24 months 


20000 mi 
(31000 km) 

or 
30 months 


1 


* 


Air filter element 


• Clean with compressed air. 

• Replace if necessary. 




V 


V 


V 


V 


V 


2 


* 


Clutch 


• Check operation. 

• Adjust or replace cable. 


V 


V 


V 


V 


V 


V 


3 


* 


Front brake 


• Check operation, fluid level, and 
for fluid leakage. 

• Replace brake pads if necessary. 


V 


V 


V 


V 


V 


V 


4 


* 


Rear brake 


• Check operation. 

• Adjust cable and replace brake 
shoes if necessary. 


V 


V 


V 


V 


V 


V 


5 


* 


Brake hose 


• Check for cracks or damage. 




V 


V 


V 


V 


V 


• Replace. 


Every 4 years 


6 


* 


Wheels 


• Check runout, spoke tightness 
and for damage. 

• Tighten spokes if necessary. 




V 


V 


V 


V 


V 


7 


* 


Tires 


• Check tread depth and for dam- 
age. 

• Replace if necessary. 

• Check air pressure. 

• Correct if necessary. 




V 


V 


V 


V 


V 


8 


* 


Wheel bearings 


• Check bearings for smooth oper- 
ation. 

• Replace if necessary. 




V 


V 


V 


V 


V 



6-4 



PERIODIC MAINTENANCE AND MINOR REPAIR 







ITEM 


ROUTINE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 
(1000 km) 

or 
1 month 


4000 mi 
(7000 km) 

or 
6 months 


8000 mi 
(13000 km) 

or 
12 months 


12000 mi 
(19000 km) 

or 
18 months 


16000 mi 
(25000 km) 

or 
24 months 


20000 mi 
(31000 km) 

or 
30 months 


9 


* 


Swingarm pivot 
bearings 


• Check bearing assemblies for 
looseness. 

• Moderately repack with lithium- 
soap-based grease. 






V 




Repack. 




10 


* 


Steering bearings 


• Check bearing assemblies for 
looseness. 

• Moderately repack with lithium- 
soap-based grease every 16000 
mi (25000 km) or 24 months. 


V 


V 


V 


V 


Repack. 


V 


11 


* 


Chassis fasteners 


• Check all chassis fitting and fas- 
teners. 

• Correct if necessary. 




V 


V 


V 


V 


V 


12 




Brake and clutch le- 
ver pivot shafts 


• Apply lithium-soap-based grease 
(all-purpose grease) lightly. 




V 


V 


V 


V 


V 


13 




Brake and shift ped- 
al pivot shafts 


• Apply lithium-soap-based grease 
(all-purpose grease) lightly. 




V 


V 


V 


V 


V 


14 




Sidestand pivot 


• Check operation. 

• Apply lithium-soap-based grease 
(all-purpose grease) lightly. 




V 


V 


V 


V 


V 


15 


* 


Sidestand switch 


• Check operation and replace if 
necessary. 


V 


V 


V 


V 


V 


V 


16 


* 


Front fork 


• Check operation and for oil leak- 
age. 

• Replace if necessary. 




V 


V 


V 


V 


V 


17 


* 


Shock absorber as- 
sembly 


• Check operation and for oil leak- 
age. 

• Replace if necessary. 




V 


V 


V 


V 


V 



6-5 



PERIODIC MAINTENANCE AND MINOR REPAIR 







ITEM 


ROUTINE 


INITIAL 


ODOMETER READINGS 


No. 


600 mi 
(1000 km) 

or 
1 month 


4000 mi 
(7000 km) 

or 
6 months 


8000 mi 
(13000 km) 

or 
12 months 


12000 mi 
(19000 km) 

or 
18 months 


16000 mi 
(25000 km) 

or 
24 months 


20000 mi 
(31000 km) 

or 
30 months 


18 




Engine oil 


• Change (warm engine before 
draining). 


V 


V 


V 


V 


V 


V 


19 




Engine oil filter ele- 
ment 


• Replace. 


V 




V 




V 




20 




Final gear oil 


• Check oil level and for oil leakage. 

• Change at initial 600 mi (1000 
km) or 1 month, and thereafter 
every 1 6000 mi (25000 km) or 24 
months. 


Change. 


V 


V 


V 


Change. 


V 


21 


* 


Control and meter 
cables 


• Apply Yamaha chain and cable 
lube or engine oil 10W-30 thor- 
oughly. 


V 


V 


V 


V 


V 


V 


22 


* 


Throttle grip hous- 
ing and cable 


• Check operation and free play. 

• Adjust the throttle cable free play 
if necessary. 

• Lubricate the throttle grip housing 
and cable. 




V 


V 


V 


V 


V 



* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 
NOTE: 



From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. 



NOTE: 

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 

6-6 



PERIODIC MAINTENANCE AND MINOR REPAIR 

• Hydraulic brake system 

• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level 
regularly and fill as required. 

• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 

• Replace the brake hoses every four years or if cracked or damaged. 



6-7 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Removing and installing 
panels 

The panels shown need to be removed 
to perform some of the maintenance 
jobs described in this chapter. Refer to 
this section each time a panel needs to 
be removed and installed. 



XVS650 



"—^ 




1 . Panel A 



XVS650A/AT 



XVS650 





1 . Panel A 



1. Bolt 

To install the panel 

Place the panel in the original position, 

and then install the bolts. 




1 . Panel B 



Panel A 



To remove the panel 1. Bolt 

Remove the bolts, and then take the 
panel off. 



6-8 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Panel B 

To remove the panel 
Remove the bolt, and then pull the pan- 
el off as shown. 




1. Bolt 



To install the panel 

Place the panel in the original position, 

and then install the bolt. 




Checking the spark plugs 

The spark plugs are important engine 
components, which are easy to check. 
Since heat and deposits will cause any 
spark plug to slowly erode, the spark 
plugs should be removed and checked 
in accordance with the periodic mainte- 
nance and lubrication chart. In addition, 
the condition of the spark plugs can re- 
veal the condition of the engine. 

To remove a spark plug 

1 . Remove the spark plug cap. 




1 . Spark plug cap 

2. Remove the spark plug as shown, 
with the spark plug wrench includ- 
ed in the owner's tool kit. 

6-9 




1. Spark plug wrench 

To check the spark plugs 

1 . Check that the porcelain insulator 
around the center electrode on 
each spark plug is a medium-to- 
light tan (the ideal color when the 
vehicle is ridden normally). 

2. Check that all spark plugs installed 
in the engine have the same color. 

NOTE: 

If any spark plug shows a distinctly dif- 
ferent color, the engine could be defec- 
tive. Do not attempt to diagnose such 
problems yourself. Instead, have a 
Yamaha dealer check the vehicle. 



PERIODIC MAINTENANCE AND MINOR REPAIR 



3. Check each spark plug for elec- 
trode erosion and excessive car- 
bon or other deposits, and replace 
it if necessary. 



Specified spark plug: 

NGK/DPR7EA-9 
DENSO/X22EPR-U9 



To install a spark plug 

1. Measure the spark plug gap with a 
wire thickness gauge and, if nec- 
essary, adjust the gap to specifica- 
tion. 




1. Spark plug gap 



Spark plug gap: 

0.8-0.9 mm (0.031-0.035 in) 



Clean the surface of the spark plug 
gasket and its mating surface, and 
then wipe off any grime from the 
spark plug threads. 
Install the spark plug with the 
spark plug wrench, and then tight- 
en it to the specified torque. 



Canister (for California only) 



---- -To fuel tank 

,--- ■» To carburetor 



Tightening torque: 

Spark plug: 

17.5 Nm (1.75m-kgf, 13 ft-lbf) 



NOTE: 

If a torque wrench is not available when 
installing a spark plug, a good estimate 
of the correct torque is 1/4-1/2 turn 
past finger tight. However, the spark 
plug should be tightened to the speci- 
fied torque as soon as possible. 

4. Install the spark plug cap. 




Canister 



Vent hose 



This model is equipped with a canister 
to prevent the discharging of fuel vapor 
into the atmosphere. 

• Check each hose connection. 

• Check each hose and canister for 
cracks or damage. Replace if dam- 
aged. 

• Make sure the vent hose is not 
blocked. Clean it if necessary. 



6-10 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Engine oil and oil filter 
element 

The engine oil level should be checked 
before each ride. In addition, the oil 
must be changed and the oil filter ele- 
ment replaced at the intervals specified 
in the periodic maintenance and lubri- 
cation chart. 

To check the engine oil level 

1. Place the vehicle on a level sur- 
face and hold it in an upright posi- 
tion. 

NOTE: 

Make sure that the vehicle is positioned 
straight up when checking the oil level. 
A slight tilt to the side can result in a 
false reading. 

2. Start the engine, warm it up for 
several minutes, and then turn it 
off. 

3. Wait a few minutes until the oil set- 
tles, and then check the oil level 
through the check window located 
at the bottom-left side of the crank- 
case. 



NOTE: 

The engine oil should be between the 
minimum and maximum level marks. 



Place an oil pan under the engine 
to collect the used oil. 
Remove the engine oil filler cap 
and drain bolt to drain the oil from 
the crankcase. 




1 . Engine oil level check window 

2. Maximum level mark 

3. Minimum level mark 

4. Engine oil filler cap 

4. If the engine oil is at or below the 
minimum level mark, add sufficient 
oil of the recommended type to 
raise it to the correct level. 

To change the engine oil (with or 
without oil filter element replace- 
ment) 

1. Start the engine, warm it up for 
several minutes, and then turn it 
off. 



1. Engine oil filler bolt 

2. Oil pan 

NOTE: 



Skip steps 4-7 if the oil filter element is 
not being replaced. 

4. Remove the outer and inner oil fil- 
ter element covers by removing 
the bolts. 



6-11 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1 . Outer oil filter element cover 

2. Bolt 




1. Inner oil filter element cover 

2. Bolt 

5. Remove the oil filter element and 
O-ring. 



1. Oil filter element 

2. O-ring 

6. Install a new oil filter element and 
the O-ring. 

7. Install the oil filter element covers 
by installing the bolts, and then 
tighten them to the specified 
torque. 



Tightening torque: 

Oil filter element cover bolt: 
10Nm(1.0m-kgf, 7 ft-lbf) 



8. Install the engine oil drain bolt, and 
then tighten it to the specified 
torque. 

NOTE: 

Check the washer for damage and re- 
place it if necessary. 



Tightening torque: 

Engine oil drain bolt: 
43 Nm (4.3 m-kgf, 31 ft-lbf) 



Add the specified amount of the 
recommended oil, and then install 
and tighten the oil filler cap. 



Recommended engine oil: 


See page 8-1. 


Oil quantity: 


Without oil filter element replace- 


ment: 


2.60 L (2.75 US qt) (2.29 Imp.qt) 


With oil filter element replacement: 


2.80 L (2.96 US qt) (2.46 Imp.qt) 



CAUTION: 



• In order to prevent clutch slip- 
page (since the engine oil also 
lubricates the clutch), do not 
mix any chemical additives. Do 
not use oils with a diesel speci- 
fication of "CD" or oils of a high- 
er quality than specified. In 
addition, do not use oils labeled 
"ENERGY CONSERVING II" or 
higher. 



6-12 



PERIODIC MAINTENANCE AND MINOR REPAIR 



• Make sure that no foreign mate- 
rial enters the crankcase. 

1 0. Start the engine, and then let it idle 
for several minutes while checking 
it for oil leakage. If oil is leaking, im- 
mediately turn the engine off and 
check for the cause. 

11. Turn the engine off, and then 
check the oil level and correct it if 
necessary. 



Final gear oil 

The final gear case must be checked 
for oil leakage before each ride. If any 
leakage is found, have a Yamaha deal- 
er check and repair the vehicle. In addi- 
tion, the final gear oil level must be 
checked and the oil changed as follows 
at the intervals specified in the periodic 
maintenance and lubrication chart. 



A WARNING 



• Make sure that no foreign mate- 
rial enters the final gear case. 

• Make sure that no oil gets on the 
tire or wheel. 

To check the final gear oil level 

1. Place the vehicle on a level sur- 
face and hold it in an upright posi- 
tion. 

NOTE: 



The final gear oil level must be 
checked on a cold engine. 
Make sure that the vehicle is posi- 
tioned straight up when checking 
the oil level. A slight tilt to the side 
can result in a false reading. 



2. Remove the oil filler bolt, and then 
check the oil level in the final gear 
case. 

NOTE: 

The oil level should be at the brim of the 
filler hole. 




1 . Final gear oil drain bolt 

2. Final gear oil filler bolt 

3. Correct oil level 

3. If the oil is below the brim of the fill- 
er hole, add sufficient oil of the rec- 
ommended type to raise it to the 
correct level. 

To change the final gear oil 

1. Place an oil pan under the final 
gear case to collect the used oil. 



6-13 



PERIODIC MAINTENANCE AND MINOR REPAIR 



2. Remove the oil filler bolt and drain 
bolt to drain the oil from the final 
gear case. 

3. Install the final gear oil drain bolt, 
and then tighten it to the specified 
torque. 



Tightening torque: 

Final gear oil drain bolt: 
23 Nm (2.3m-kgf, 17 ft-lbf) 



4. Add the recommended final gear 
oil to the brim of the filler hole. 



Recommended final gear oil: 

SAE80 API GL-4 Hypoid gear oil 
Oil quantity: 

0.19 L (0.20 US qt) (0.17 Imp.qt) 



NOTE: 

GL4 is a quality rating. Hypoid gear oils 
rated GL5 or GL6 may also be used. 

5. Install the oil filler bolt, and then 
tighten it to the specified torque. 



Tightening torque: 

Final gear oil filler bolt: 
23 Nm (2.3m-kgf, 17 ft-lbf) 



6. Check the final gear case for oil 
leakage. If oil is leaking, check for 
the cause. 



Cleaning the air filter element 

The air filter element should be cleaned 
at the intervals specified in the periodic 
maintenance and lubrication chart. 
Clean the air filter element more fre- 
quently if you are riding in unusually 
wet or dusty areas. 
1. Remove the air filter case cover by 
removing the bolts. 




1 . Air filter case cover 

2. Bolt 

2. Pull the air filter element out. 

3. Lightly tap the air filter element to 
remove most of the dust and dirt, 
and then blow the remaining dirt 
out with compressed air as shown. 
If the air filter element is damaged, 
replace it. 



6-14 



PERIODIC MAINTENANCE AND MINOR REPAIR 



CAUTION: 




1. Air filter element 

4. Insert the air filter element into the 
air filter case as shown. 



Make sure that the air filter ele- 
ment is properly seated in the 
air filter case. 

The engine should never be op- 
erated without the air filter ele- 
ment installed, otherwise the 
piston(s) and/or cylinder(s) may 
become excessively worn. 

Install the air filter case cover by 
aligning the match marks and in- 
stalling the bolts. 



NOTE: 

If dust or water collects in the air filter 
check hose, remove the clamp from it, 
and then remove the plug to drain the 
hose. 




1 . Air filter element holder 

2. Projection 

3. Slot 



1 . Match marks 




1. Air filter check hose 



6-15 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Adjusting the carburetors 

The carburetors are important parts of 
the engine and emission control sys- 
tem, which require very sophisticated 
adjustment. Therefore, all carburetor 
adjustments should be left to a Yamaha 
dealer, who has the necessary profes- 
sional knowledge and experience. 



Adjusting the throttle cable 
free play 




Throttle cable free play 



The throttle cable free play should mea- 
sure 4.0-6.0 mm (0.16-0.24 in) at the 
throttle grip. Periodically check the 
throttle cable free play and, if neces- 
sary, have a Yamaha dealer adjust it. 



Adjusting the valve clearance 

The valve clearance changes with use, 
resulting in improper air-fuel mixture 
and/or engine noise. To prevent this 
from occurring, the valve clearance 
must be adjusted by a Yamaha dealer 
at the intervals specified in the periodic 
maintenance and lubrication chart. 



6-16 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Tires 

To maximize the performance, durabil- 
ity, and safe operation of your motor- 
cycle, note the following points 
regarding the specified tires. 

Tire air pressure 

The tire air pressure should be checked 
and, if necessary, adjusted before each 
ride. 



A WARNING 



• The tire air pressure must be 
checked and adjusted on cold 
tires (i.e., when the temperature 
of the tires equals the ambient 
temperature). 

• The tire air pressure must be ad- 
justed in accordance with the 
riding speed and with the total 
weight of rider, passenger, car- 
go, and accessories approved 
for this model. 



Tire air pressure (measured on cold 
tires): 

0-90 kg (0-198 lb): 

Front: 

XVS650 200 kPa (29 psi) (2.00 

kgf/cm 2 ) 

XVS650A 225 kPa (33 psi) 

(2.25 kgf/cm 2 ) 

XVS650AT 225 kPa (33 psi) 

(2.25 kgf/cm 2 ) 
Rear: 

225 kPa (33 psi) (2.25 kgf/cm 2 ) 
XVS650 90-178 kg (198-392 lb) 
(CAL) 

XVS650 90-180 kg (198-397 lb) 
(U49) 

XVS650A 90-198 kg (198-437 lb) 
(CAL) 

XVS650A 90-200 kg (198-441 lb) 
(U49) 

XVS650AT 90-198 kg (198-437 lb) 
(CAL) 

XVS650AT 90-200 kg (198-441 lb) 
(U49): 
Front: 

XVS650 200 kPa (29 psi) (2.00 

kgf/cm 2 ) 

XVS650A 225 kPa (33 psi) 

(2.25 kgf/cm 2 ) 

XVS650AT 225 kPa (33 psi) 

(2.25 kgf/cm 2 ) 
Rear: 

250 kPa (36 psi) (2.50 kgf/cm 2 ) 



Maximum load*: 

XVS650 178 kg (392 lb) (CAL) 
XVS650 180 kg (397 lb) (U49) 
XVS650A 198 kg (437 lb) (CAL) 
XVS650A 200 kg (441 lb) (U49) 
XVS650AT 1 98 kg (437 lb) (CAL) 
XVS650AT 200 kg (441 lb) (U49) 
* Total weight of rider, passenger, car- 
go and accessories 



A WARNING 



Proper loading of your vehicle is im- 
portant for several characteristics of 
your vehicle, such as handling, 
braking, performance and safety. Do 
not carry loosely packed items that 
can shift. Securely pack your heavi- 
est items close to the center of the 
vehicle, and distribute the weight 
evenly from side to side. Properly 
adjust the suspension for your load, 
and check the condition and pres- 
sure of your tires. NEVER OVER- 
LOAD YOUR VEHICLE. Make sure 
that the total weight of the cargo, rid- 
er, passenger, and accessories 
(cowling, saddlebags, etc. if ap- 
proved for this model) does not ex- 
ceed the maximum load of the 



6-17 



PERIODIC MAINTENANCE AND MINOR REPAIR 



vehicle. Operation of an overloaded 
vehicle could cause tire damage, an 
accident, or even injury. 

Tire inspection 




1 . Tire sidewall 

2. Tire wear indicator 

3. Tire tread depth 

Always check the tires before operating 
the motorcycle. If a tire tread shows 
crosswise lines (minimum tread depth), 
if the tire has a nail or glass fragments 
in it, or if the sidewall is cracked, con- 
tact a Yamaha dealer immediately and 
have the tire replaced. 



Minimum tire tread depth (front and 
rear): 

1.0 mm (0.04 in) 



A WARNING 



• It is dangerous to ride with a 
worn-out tire. When a tire tread 
begins to show crosswise lines, 
have a Yamaha dealer replace 
the tire immediately. 

• The replacement of all wheel- 
and brake-related parts, includ- 
ing the tires, should be left to a 
Yamaha dealer, who has the 
necessary professional knowl- 
edge and experience. 

• It is not recommended to patch 
a punctured tube. If unavoid- 
able, however, patch the tube 
very carefully and replace it as 
soon as possible with a high- 
quality product. 

Tire information 

This motorcycle is equipped with spoke 
wheels and tube tires. 



A WARNING 



The front and rear tires should 
be of the same make and de- 
sign, otherwise the handling 
characteristics of the vehicle 
cannot be guaranteed. 
After extensive tests, only the 
tires listed below have been ap- 
proved for this model by 
Yamaha Motor Co., Ltd. 



6-18 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Front tire: 

Size: 

XVS650 1 00/90-1 9M/C 57S 

XVS650A 1 30/90-1 6M/C 67S 

XVS650AT 1 30/90-1 6M/C 67S 
Manufacturer/model: 

XVS650 BRIDGESTONE/EXE- 

DRA L309 

XVS650A BRIDGESTONE/EXE- 

DRA G703 

XVS650AT BRIDGESTONE/EXE- 

DRA G703 

XVS650 DUNLOP/F24 

XVS650A DUNLOP/D404F 

XVS650AT DUNLOP/D404F 
Rear tire: 
Size: 

1 70/80-1 5M/C77S 
Manufacturer/model: 

XVS650 BRIDGESTONE/EXE- 

DRA G546 

XVS650A BRIDGESTONE/EXE- 

DRA G702 

XVS650AT BRIDGESTONE/EXE- 

DRA G702 

XVS650 DUNLOP/K555 

XVS650A DUNLOP/D404G 

XVS650AT DUNLOP/D404G 



Spoke wheels 

To maximize the performance, durabil- 
ity, and safe operation of your motor- 
cycle, note the following points 
regarding the specified wheels. 

• The wheel rims should be checked 
for cracks, bends or warpage, and 
the spokes for looseness or dam- 
age before each ride. If any dam- 
age is found, have a Yamaha 
dealer replace the wheel. Do not 
attempt even the smallest repair to 
the wheel. A deformed or cracked 
wheel must be replaced. 

• The wheel should be balanced 
whenever either the tire or wheel 
has been changed or replaced. An 
unbalanced wheel can result in 
poor performance, adverse han- 
dling characteristics, and a short- 
ened tire life. 

• Ride at moderate speeds after 
changing a tire since the tire sur- 
face must first be "broken in" for it 
to develop its optimal characteris- 
tics. 



Accessories and replacement 
parts 



A WARNING 



This vehicle is not designed to pull a 
trailer or to be attached to a sidecar. 
The accessories or replacement 
parts you choose for your vehicle 
should be designed specifically for 
this model, and they must be se- 
curely mounted to maintain the in- 
herent stability of the original 
design. Genuine Yamaha Parts and 
Accessories are designed and test- 
ed to be compatible with your vehi- 
cle. Please consider Genuine 
Yamaha Parts and Accessories be- 
fore making a purchase. Use of non- 
Yamaha-approved accessories or 
replacement parts may cause loss of 
handling stability and riding safety. 
Since Yamaha cannot control the 
quality of accessories or parts man- 
ufactured by other companies, 
Yamaha cannot be held liable for 



6-19 



PERIODIC MAINTENANCE AND MINOR REPAIR 



any consequences caused by the ... .. .. .... "U22041 

use of items which have not been Adjusting the clutch lever free 
approved by Yamaha. P' a Y 




1. Locknut 

2. Clutch lever free play adjusting bolt 

3. Clutch lever free play 

The clutch lever free play should mea- 
sure XVS650 10.0-15.0 mm (0.39- 
0.59 in) 

XVS650A 5.0-10.0 mm (0.20-0.39 in) 
XVS650AT 5.0-10.0 mm (0.20-0.39 
in) as shown. Periodically check the 
clutch lever free play and, if necessary, 
adjust it as follows. 
1 . Loosen the locknut at the clutch le- 
ver. 



2. To increase the clutch lever free 
play, turn the adjusting bolt in di- 
rection (a). To decrease the clutch 
lever free play, turn the adjusting 
bolt in direction (b). 

NOTE: 

If the specified clutch lever free play 
could be obtained as described above, 
tighten the locknut and skip the rest of 
the procedure, otherwise proceed as 
follows. 

3. Fully turn the adjusting bolt at the 
clutch lever in direction (a) to loos- 
en the clutch cable. 

4. Loosen the locknut at the crank- 
case. 




1 . Clutch lever free play adjusting nut (crank- 
case) 

2. Locknut 



6-20 



PERIODIC MAINTENANCE AND MINOR REPAIR 



5. To increase the clutch lever free 
play, turn the adjusting nut in direc- 
tion (a). To decrease the clutch le- 
ver free play, turn the adjusting nut 
in direction (b). 

6. Tighten the locknut at the clutch le- 
ver and the crankcase. 



Adjusting the brake lever free 
play 




Brake lever free play 



The brake lever free play should mea- 
sure 10.0-15.0 mm (0.39-0.59 in) as 
shown. Periodically check the brake le- 
ver free play and, if necessary, adjust it 
as follows. 




1. Locknut 

2. Brake lever free play adjusting screw 

1 . Loosen the locknut at the brake le- 
ver. 

2. To increase the brake lever free 
play, turn the adjusting screw in di- 
rection (a). To decrease the brake 
lever free play, turn the adjusting 
screw in direction (b). 

3. Tighten the locknut. 



A WARNING 



After adjusting the brake lever 
free play, check the free play 
and make sure that the brake is 
working properly. 
A soft or spongy feeling in the 
brake lever can indicate the 
presence of air in the hydraulic 



6-21 



PERIODIC MAINTENANCE AND MINOR REPAIR 



system. If there is air in the hy- 
draulic system, have a Yamaha 
dealer bleed the system before 
operating the motorcycle. Air in 
the hydraulic system will dimin- 
ish the braking performance, 
which may result in loss of con- 
trol and an accident. 



Adjusting the brake pedal 
position and free play 

XVS650 




1 . Distance between brake pedal and footrest 

2. Brake pedal free play 

XVS650A/AT 




A WARNING 



It is advisable to have a Yamaha 
dealer make these adjustments. 

NOTE: 

The brake pedal position should be ad- 
justed before adjusting the brake pedal 
free play. 

Brake pedal position 

The brake pedal should be positioned 
approximately XVS650 102.0 mm 
(4.02 in) 

XVS650A 108.0 mm (4.25 in) 
XVS650AT 108.0 mm (4.25 in) above 
the top of the footrest as shown. Peri- 
odically check the brake pedal position 
and, if necessary, adjust it as follows. 

1. Loosen the locknut at the brake 
pedal. 

2. To raise the brake pedal, turn the 
adjusting bolt in direction (a). To 
lower the brake pedal, turn the ad- 
justing bolt in direction (b). 



1 . Distance between brake pedal and footrest 

2. Brake pedal free play 



6-22 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Locknut 

2. Brake pedal position adjusting bolt 

3. Tighten the locknut. 



A WARNING 



After adjusting the brake pedal posi- 
tion, the brake pedal free play must 
be adjusted. 

Brake pedal free play 

The brake pedal free play should mea- 
sure 20.0-30.0 mm (0.79-1.18 in) at 
the brake pedal end. Periodically check 
the brake pedal free play and, if neces- 
sary, adjust it as follows. 



To increase the brake pedal free play, 
turn the adjusting nut at the brake rod in 
direction (a). To decrease the brake 
pedal free play, turn the adjusting nut in 
direction (b). 



Adjusting the rear brake light 
switch 




1. Brake pedal free play adjusting nut 



1 . Rear brake light switch 

2. Rear brake light switch adjusting nut 

The rear brake light switch, which is ac- 
tivated by the brake pedal, is properly 
adjusted when the brake light comes 
on just before braking takes effect. If 
necessary, adjust the brake light switch 
as follows. 

Turn the adjusting nut while holding the 
rear brake light switch in place. To 
make the brake light come on earlier, 
turn the adjusting nut in direction (a). To 
make the brake light come on later, turn 
the adjusting nut in direction (b). 



6-23 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Checking the front brake pads 
and rear brake shoes 

The front brake pads and the rear brake 
shoes must be checked for wear at the 
intervals specified in the periodic main- 
tenance and lubrication chart. 

EAU22430 

Front brake pads 




Brake pad wear indicator groove 



Each front brake pad is provided with 
wear indicator grooves, which allow 
you to check the brake pad wear with- 
out having to disassemble the brake. 
To check the brake pad wear, check 
the wear indicator grooves. If a brake 
pad has worn to the point that the wear 



indicator grooves have almost disap- 
peared, have a Yamaha dealer replace 
the brake pads as a set. 

EAU22540 

Rear brake shoes 



Checking the brake fluid level 




1 . Brake shoe wear limit line 

2. Brake shoe wear indicator 

The rear brake is provided with a wear 
indicator, which allows you to check the 
brake shoe wear without having to dis- 
assemble the brake. To check the 
brake shoe wear, check the position of 
the wear indicator while applying the 
brake. If a brake shoe has worn to the 
point that the wear indicator reaches 
the wear limit line, have a Yamaha 
dealer replace the brake shoes as a 
set. 




1. Minimum level mark 

Insufficient brake fluid may allow air to 
enter the brake system, possibly caus- 
ing it to become ineffective. 
Before riding, check that the brake fluid 
is above the minimum level mark and 
replenish if necessary. A low brake fluid 
level may indicate worn brake pads 
and/or brake system leakage. If the 
brake fluid level is low, be sure to check 
the brake pads for wear and the brake 
system for leakage. 
Observe these precautions: 
• When checking the fluid level, 
make sure that the top of the mas- 
ter cylinder is level by turning the 
handlebars. 



6-24 



PERIODIC MAINTENANCE AND MINOR REPAIR 



• Use only the recommended quality 
brake fluid, otherwise the rubber 
seals may deteriorate, causing 
leakage and poor braking perfor- 
mance. 



Recommended brake fluid: 

DOT 4 



• Refill with the same type of brake 
fluid. Mixing fluids may result in a 
harmful chemical reaction and 
lead to poor braking performance. 

• Be careful that water does not en- 
ter the master cylinder when refill- 
ing. Water will significantly lower 
the boiling point of the fluid and 
may result in vapor lock. 

• Brake fluid may deteriorate paint- 
ed surfaces or plastic parts. Al- 
ways clean up spilled fluid 
immediately. 

• As the brake pads wear, it is nor- 
mal for the brake fluid level to grad- 
ually go down. However, if the 
brake fluid level goes down sud- 
denly, have a Yamaha dealer 
check the cause. 



Changing the brake fluid 

Have a Yamaha dealer change the 
brake fluid at the intervals specified in 
the NOTE after the periodic mainte- 
nance and lubrication chart. In addition, 
have the oil seals of the brake master 
cylinder and caliper as well as the 
brake hose replaced at the intervals 
listed below or whenever they are dam- 
aged or leaking. 

• Oil seals: Replace every two 
years. 

• Brake hose: Replace every four 
years. 



Checking and lubricating the 
cables 

The operation of all control cables and 
the condition of the cables should be 
checked before each ride, and the ca- 
bles and cable ends should be lubricat- 
ed if necessary. If a cable is damaged 
or does not move smoothly, have a 
Yamaha dealer check or replace it. 



Recommended lubricant: 

Yamaha Chain and Cable Lube or 
engine oil SAE 10W-30 (API SE) 



A WARNING 



Damage to the outer housing of ca- 
bles may result in internal rusting 
and cause interference with cable 
movement. Replace damaged ca- 
bles as soon as possible to prevent 
unsafe conditions. 



6-25 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Checking and lubricating the 
throttle grip and cable 

The operation of the throttle grip should 
be checked before each ride. In addi- 
tion, the cable should be lubricated or 
replaced at the intervals specified in the 
periodic maintenance chart. 



Checking and lubricating the 
brake and shift pedals 



Checking and lubricating the 
brake and clutch levers 





The operation of the brake and shift 
pedals should be checked before each 
ride, and the pedal pivots should be lu- 
bricated if necessary. 



Recommended lubricant: 

Lithium-soap-based grease (all-pur- 
pose grease) 



The operation of the brake and clutch 
levers should be checked before each 
ride, and the lever pivots should be lu- 
bricated if necessary. 



Recommended lubricant: 

Lithium-soap-based grease (all-pur- 
pose grease) 



6-26 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Checking and lubricating the 
sidestand 




The operation of the sidestand should 
be checked before each ride, and the 
sidestand pivot and metal-to-metal 
contact surfaces should be lubricated if 
necessary. 



A WARNING 



If the sidestand does not move up 
and down smoothly, have a Yamaha 
dealer check or repair it. 



Recommended lubricant: 

Lithium-soap-based grease (all-pur- 
pose grease) 



Checking the front fork 

The condition and operation of the front 
fork must be checked as follows at the 
intervals specified in the periodic main- 
tenance and lubrication chart. 

To check the condition 



A WARNING 



Securely support the vehicle so that 
there is no danger of it falling over. 

Check the inner tubes for scratches, 
damage and excessive oil leakage. 

To check the operation 

1. Place the vehicle on a level sur- 
face and hold it in an upright posi- 
tion. 

2. While applying the front brake, 
push down hard on the handlebars 
several times to check if the front 
fork compresses and rebounds 
smoothly. 




CAUTION: 

If any damage is found or the front 
fork does not operate smoothly, 
have a Yamaha dealer check or re- 
pair it. 



6-27 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Checking the steering 

Worn or loose steering bearings may 
cause danger. Therefore, the operation 
of the steering must be checked as fol- 
lows at the intervals specified in the pe- 
riodic maintenance and lubrication 
chart. 
1 . Place a stand under the engine to 
raise the front wheel off the 
ground. 



A WARNING 




Securely support the vehicle so that 
there is no danger of it falling over. 

2. Hold the lower ends of the front 
fork legs and try to move them for- 
ward and backward. If any free 
play can be felt, have a Yamaha 
dealer check or repair the steering. 



Checking the wheel bearings 

The front and rear wheel bearings must 
be checked at the intervals specified in 
the periodic maintenance and lubrica- 
tion chart. If there is play in the wheel 
hub or if the wheel does not turn 
smoothly, have a Yamaha dealer check 
the wheel bearings. 



6-28 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Battery 

The battery is located behind panel B. 
(See page 6-8.) 

This model is equipped with a sealed- 
type (MF) battery, which does not re- 
quire any maintenance. There is no 
need to check the electrolyte or to add 
distilled water. 

ECA10620 

CAUTION: 



Never attempt to remove the battery 
cell seals, as this would permanent- 
ly damage the battery. 



A WARNING 



Electrolyte is poisonous and 
dangerous since it contains sul- 
furic acid, which causes severe 
burns. Avoid any contact with 
skin, eyes or clothing and al- 
ways shield your eyes when 
working near batteries. In case 
of contact, administer the fol- 
lowing FIRST AID. 
• EXTERNAL: Flush with plenty 
of water. 



• INTERNAL: Drink large quan- 
tities of water or milk and im- 
mediately call a physician. 

• EYES: Flush with water for 15 
minutes and seek prompt 
medical attention. 

• Batteries produce explosive hy- 
drogen gas. Therefore, keep 
sparks, flames, cigarettes, etc., 
away from the battery and pro- 
vide sufficient ventilation when 
charging it in an enclosed 
space. 

• KEEP THIS AND ALL BATTER- 
IES OUT OF THE REACH OF 
CHILDREN. 

To charge the battery 

Have a Yamaha dealer charge the bat- 
tery as soon as possible if it seems to 
have discharged. Keep in mind that the 
battery tends to discharge more quickly 
if the vehicle is equipped with optional 
electrical accessories. 



To store the battery 

1 . If the vehicle will not be used for 
more than one month, remove the 
battery, fully charge it, and then 
place it in a cool, dry place. 

2. If the battery will be stored for more 
than two months, check it at least 
once a month and fully charge it if 
necessary. 

3. Fully charge the battery before in- 
stallation. 

4. After installation, make sure that 
the battery leads are properly con- 
nected to the battery terminals. 

ECA10630 

CAUTION: 



• Always keep the battery 
charged. Storing a discharged 
battery can cause permanent 
battery damage. 

• To charge a sealed-type (MF) 
battery, a special (constant-volt- 
age) battery charger is required. 
Using a conventional battery 
charger will damage the battery. 
If you do not have access to a 



6-29 



PERIODIC MAINTENANCE AND MINOR REPAIR 



sealed-type (MF) battery charg- 
er, have a Yamaha dealer 
charge your battery. 



Replacing the fuses 




1 . Fuse box 

2. Main fuse 

3. Spare main fuse 

The main fuse and the fuse box, which 
contains the fuses for the individual cir- 
cuits, are located behind panel B. (See 
page 6-8.) 
If a fuse is blown, replace it as follows. 

1 . Turn the key to "OFF" and turn off 
the electrical circuit in question. 

2. Remove the blown fuse, and then 
install a new fuse of the specified 
amperage. 




1. Headlight fuse 

2. Signaling system fuse 

3. Ignition fuse 

4. Carburetor heater fuse 

5. Ignitor unit fuse (for California only) 

6. Spare fuse 

7. Spare fuse (for California only) 



6-30 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Specified fuses: 

Main fuse: 

30.0 A 
Signaling system fuse: 

10.0 A 
Ignition fuse: 

10.0A 
Headlight fuse: 

15.0A 
Carburetor heater fuse: 

15.0A 
Ignitor unit fuse: 

XVS650 5.0 A (CAL) 

XVS650A 5.0 A (CAL) 

XVS650AT 5.0 A (CAL) 



CAUTION: 



Do not use a fuse of a higher amper- 
age rating than recommended to 
avoid causing extensive damage to 
the electrical system and possibly a 
fire. 

3. Turn the key to "ON" and turn on 
the electrical circuit in question to 
check if the device operates. 

4. If the fuse immediately blows 
again, have a Yamaha dealer 
check the electrical system. 



Replacing the headlight bulb 

This model is equipped with a quartz 
bulb headlight. If the headlight bulb 
burns out, replace it as follows. 
1. Remove the headlight unit by re- 
moving the screws. 





1. Headlight coupler 

2. Headlight bulb cover 

3. Unhook the headlight bulb holder, 
and then remove the defective 
bulb. 



1. Screw 

2. Disconnect the headlight coupler, 
and then remove the bulb cover. 




1. Headlight bulb holder 



6-31 



PERIODIC MAINTENANCE AND MINOR REPAIR 



A WARNING 



Headlight bulbs get very hot. There- 
fore, keep flammable products away 
from a lit headlight bulb, and do not 
touch the bulb until it has cooled 
down. 

4. Place a new headlight bulb into po- 
sition, and then secure it with the 
bulb holder. 



CAUTION: 



Do not touch the glass part of the 
headlight bulb to keep it free from 
oil, otherwise the transparency of 
the glass, the luminosity of the bulb, 
and the bulb life will be adversely af- 
fected. Thoroughly clean off any dirt 
and fingerprints on the headlight 
bulb using a cloth moistened with al- 
cohol or thinner. 




Replacing a turn signal light 
bulb or the tail/brake light bulb 

1 . Remove the lens by removing the 
screws. 



1 . Do not touch the glass part of the bulb. 

5. Install the headlight bulb cover, 
and then connect the coupler. 

6. Install the headlight unit by install- 
ing the screws. 

7. Have a Yamaha dealer adjust the 
headlight beam if necessary. 




-1 



Screw 



XVS650 




1. Screw 



6-32 



PERIODIC MAINTENANCE AND MINOR REPAIR 



XVS650A/AT 




1. Screw 

2. Remove the defective bulb by 
pushing it in and turning it counter- 
clockwise. 

3. Insert a new bulb into the socket, 
push it in, and then turn it clock- 
wise until it stops. 

4. Install the lens by installing the 
screws. 

ECA10680 

CAUTION: 



Do not overtighten the screws, oth- 
erwise the lens may break. 



Supporting the motorcycle 

Since this model is not equipped with a 
centerstand, follow these precautions 
when removing the front and rear 
wheel or performing other maintenance 
requiring the motorcycle to stand up- 
right. Check that the motorcycle is in a 
stable and level position before starting 
any maintenance. A strong wooden 
box can be placed under the engine for 
added stability. 

To service the front wheel 

1 . Stabilize the rear of the motorcycle 
by using a motorcycle stand or, if 
an additional motorcycle stand is 
not available, by placing a jack un- 
der the frame in front of the rear 
wheel. 

2. Raise the front wheel off the 
ground by using a motorcycle 
stand. 

To service the rear wheel 

Raise the rear wheel off the ground by 
using a motorcycle stand or, if a motor- 
cycle stand is not available, by placing 



a jack either under each side of the 
frame in front of the rear wheel or under 
each side of the swingarm. 



6-33 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Front wheel 



To remove the front wheel 



A WARNING 



• It is advisable to have a Yamaha 
dealer service the wheel. 

• Securely support the motor- 
cycle so that there is no danger 
of it falling over. 

1. Disconnect the speedometer ca- 
ble from the front wheel. 




1 . Speedometer cable 

2. Loosen the front wheel axle pinch 
bolt. 

3. Remove the rubber cap, and then 
loosen the wheel axle. 




1. Rubber cap 

2. Wheel axle 

3. Front wheel axle pinch bolt 

4. Lift the front wheel off the ground 
according to the procedure on 
page 6-33. 

5. Pull the wheel axle out, and then 
remove the wheel. 

ECA11070 

CAUTION: 

Do not apply the brake after the 
wheel has been removed together 
with the brake disc, otherwise the 
brake pads will be forced shut. 



To install the front wheel 

1. Install the speedometer gear unit 
into the wheel hub so that the pro- 
jections mesh with the slots. 




1 . Speedometer gear unit 

2. Speedometer cable 

3. Retainer 

2. Lift the wheel up between the fork 
legs. 

NOTE: 

Make sure that there is enough space 
between the brake pads before insert- 
ing the brake disc and that the slot in 
the speedometer gear unit fits over the 
retainer on the fork leg. 

3. Insert the wheel axle. 

4. Lower the front wheel so that it is 
on the ground. 



6-34 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Tighten the wheel axle and front 
wheel axle pinch bolt to the speci- 
fied torques, and then install the 
rubber cap. 



Tightening torques: 

Wheel axle: 


59 Nm (5.9 m-kgf, 43 ft-lbf) 
Front wheel axle pinch bolt: 


20 Nm (2.0 m-kgf, 14 ft-lbf) 



While applying the front brake, 

push down hard on the handlebars 

several times to check if the front 

fork compresses and rebounds 

smoothly. 

Connect the speedometer cable. 



Rear wheel 



To remove the rear wheel 



A WARNING 



• It is advisable to have a Yamaha 
dealer service the wheel. 

• Securely support the motor- 
cycle so that there is no danger 
of it falling over. 

1 . Loosen the axle nut. 




Axle nut 



Disconnect the brake torque rod 
from the brake shoe plate by re- 
moving the bolt and nut. 
Loosen the brake torque rod nut at 
the swingarm. 



Remove the brake pedal free play 
adjusting nut, and then disconnect 
the brake rod from the brake cam- 
shaft lever. 




1 . Brake pedal free play adjusting nut 

2. Brake camshaft lever 

3. Brake rod 

4. Bolt and nut (shoe plate) 

5. Brake torque rod 

6. Nut 

5. Remove panel A. (See page 6-8.) 

6. Remove the bolts that secure the 
final gear case to the swingarm. 



6-35 



PERIODIC MAINTENANCE AND MINOR REPAIR 




1. Bolt 

2. Final gear case 

7. Lift the rear wheel off the ground 
according to the procedure on 
page 6-33. 

8. While supporting the drive shaft, 
pull the rear wheel back to remove 
the following parts as an assem- 
bly: wheel, wheel axle, final gear 
case, and drive shaft. 

NOTE: 

Make sure to support the drive shaft as 
it is being pulled out. 



To install the rear wheel 

1 . Install the rear wheel, wheel axle, 
final gear case, and drive shaft by 
pushing the wheel forward and 
guiding the drive shaft into the mid- 
dle gear universal joint. 




1. Middle gear universal joint 

2. Drive shaft 

2. Install the final gear case bolts. 

3. Install the brake rod onto the brake 
camshaft lever, and then install the 
brake pedal free play adjusting nut 
onto the brake rod. 

4. Install the brake torque rod bolt 
and nut at the brake shoe plate. 

5. Install the panel. 

6. Lower the rear wheel so that it is 
on the ground. 



7. Tighten the axle nut, the final gear 
case bolts and the brake torque 
rod nuts to the specified torques. 



Tightening torques: 

Axle nut: 

92 Nm (9.2 m-kgf, 67 ft-lbf) 
Final gear case bolt: 

74 Nm (7.4 m-kgf, 54 ft-lbf) 
Brake torque rod nut: 

20 Nm (2.0 m-kgf, 14 ft-lbf) 



8. Adjust the brake pedal free play. 
(See page 6-22.) 



A WARNING 



After adjusting the brake pedal free 
play, check the operation of the 
brake light. 



6-36 



PERIODIC MAINTENANCE AND MINOR REPAIR 

EAU25850 

Troubleshooting 

Although Yamaha motorcycles receive 
a thorough inspection before shipment 
from the factory, trouble may occur dur- 
ing operation. Any problem in the fuel, 
compression, or ignition systems, for 
example, can cause poor starting and 
loss of power. 

The following troubleshooting chart 
represents a quick and easy procedure 
for checking these vital systems your- 
self. However, should your motorcycle 
require any repair, take it to a Yamaha 
dealer, whose skilled technicians have 
the necessary tools, experience, and 
know-how to service the motorcycle 
properly. 

Use only genuine Yamaha replace- 
ment parts. Imitation parts may look like 
Yamaha parts, but they are often inferi- 
or, have a shorter service life and can 
lead to expensive repair bills. 



6-37 



PERIODIC MAINTENANCE AND MINOR REPAIR 



Troubleshooting chart 



A WARNING 



Keep away open flames and do not smoke while checking or working on the fuel system. 



1 Pnol 








There is enough fuel. 


Check the fuel level in 
the fuel tank. 


— ^- 










There is no fuel. 









Check the compression. 



Supply fuel. 



The engine does not start. 
Check the compression. 



2. Compression 




There is compression. 




Check the ignition. 


Operate the electric starter. 


— ►- 














There is no compression. 




Have a Yamaha dealer 
check the vehicle. 









3. Ignition 



Remove the spark plugs 
and check the electrodes. 



Wet 



Wipe off with a dry cloth and correct the 
spark plug gaps, or replace the spark plugs. 



Dry 



Have a Yamaha dealer check the vehicle. 



Open the throttle halfway and operate 
the electric starter. 



The engine does not start. 
Check the battery. 



4. Battery 




The engine turns over 
quickly. 




The battery is good. 


Operate the electric starter. 


- 














The engine turns over 
slowly. 




Check the battery lead connections, 
and charge the battery if necessary. 









The engine does not start. 
Have a Yamaha dealer 
check the vehicle. 



6-38 



MOTORCYCLE CARE AND STORAGE 



Care 

While the open design of a motorcycle 
reveals the attractiveness of the tech- 
nology, it also makes it more vulnera- 
ble. Rust and corrosion can develop 
even if high-quality components are 
used. A rusty exhaust pipe may go un- 
noticed on a car, however, it detracts 
from the overall appearance of a motor- 
cycle. Frequent and proper care does 
not only comply with the terms of the 
warranty, but it will also keep your 
motorcycle looking good, extend its life 
and optimize its performance. 

Before cleaning 

1 . Cover the muffler outlets with plas- 
tic bags after the engine has 
cooled down. 

2. Make sure that all caps and covers 
as well as all electrical couplers 
and connectors, including the 
spark plug caps, are tightly in- 
stalled. 

3. Remove extremely stubborn dirt, 
like oil burnt onto the crankcase, 
with a degreasing agent and a 
brush, but never apply such prod- 



ucts onto seals, gaskets and wheel 
axles. Always rinse the dirt and de- 
greaser off with water. 



Cleaning 
CAUTION: 



• Avoid using strong acidic wheel 
cleaners, especially on spoked 
wheels. If such products are 
used on hard-to-remove dirt, do 
not leave the cleaner on the af- 
fected area any longer than in- 
structed. Also, thoroughly rinse 
the area off with water, immedi- 
ately dry it, and then apply a cor- 
rosion protection spray. 

• Improper cleaning can damage 
windshields, cowlings, panels 
and other plastic parts. Use only 
a soft, clean cloth or sponge 
with mild detergent and water to 
clean plastic. 

• Do not use any harsh chemical 
products on plastic parts. Be 
sure to avoid using cloths or 
sponges which have been in 
contact with strong or abrasive 
cleaning products, solvent or 

7-1 



thinner, fuel (gasoline), rust re- 
movers or inhibitors, brake flu- 
id, antifreeze or electrolyte. 

• Do not use high-pressure wash- 
ers or steam-jet cleaners since 
they cause water seepage and 
deterioration in the following ar- 
eas: seals (of wheel and swing- 
arm bearings, fork and brakes), 
electric components (couplers, 
connectors, instruments, 
switches and lights), breather 
hoses and vents. 

• For motorcycles equipped with 
a windshield: Do not use strong 
cleaners or hard sponges as 
they will cause dulling or 
scratching. Some cleaning com- 
pounds for plastic may leave 
scratches on the windshield. 
Test the product on a small hid- 
den part of the windshield to 
make sure that it does not leave 
any marks. If the windshield is 
scratched, use a quality plastic 
polishing compound after 
washing. 



MOTORCYCLE CARE AND STORAGE 



After normal use 

Remove dirt with warm water, a mild 
detergent, and a soft, clean sponge, 
and then rinse thoroughly with clean 
water. Use a toothbrush or bottlebrush 
for hard-to-reach areas. Stubborn dirt 
and insects will come off more easily if 
the area is covered with a wet cloth for 
a few minutes before cleaning. 

After riding in the rain, near the sea or 
on salt-sprayed roads 
Since sea salt or salt sprayed on roads 
during winter are extremely corrosive in 
combination with water, carry out the 
following steps after each ride in the 
rain, near the sea or on salt-sprayed 
roads. 

NOTE: 

Salt sprayed on roads in the winter may 
remain well into spring. 

1 . Clean the motorcycle with cold wa- 
ter and a mild detergent, after the 
engine has cooled down. 



CAUTION: 



Do not use warm water since it in- 
creases the corrosive action of the 
salt. 

2. After drying the motorcycle, apply 
a corrosion protection spray on all 
metal, including chrome- and nick- 
el-plated, surfaces to prevent cor- 
rosion. 

After cleaning 

1 . Dry the motorcycle with a chamois 
or an absorbing cloth. 

2. Use a chrome polish to shine 
chrome, aluminum and stainless- 
steel parts, including the exhaust 
system. (Even the thermally in- 
duced discoloring of stainless- 
steel exhaust systems can be re- 
moved through polishing.) 

3. To prevent corrosion, it is recom- 
mended to apply a corrosion pro- 
tection spray on all metal, 
including chrome- and nickel-plat- 
ed, surfaces. 

4. Use spray oil as a universal clean- 
er to remove any remaining dirt. 



5. Touch up minor paint damage 
caused by stones, etc. 

6. Wax all painted surfaces. 

7. Let the motorcycle dry completely 
before storing or covering it. 



A WARNING 



• Make sure that there is no oil or 
wax on the brakes or tires. 

• If necessary, clean the brake 
discs and brake linings with a 
regular brake disc cleaner or ac- 
etone, and wash the tires with 
warm water and a mild deter- 
gent. Before riding at higher 
speeds, test the motorcycle's 
braking performance and cor- 
nering behavior. 

ECA10800 

CAUTION: 



• Apply spray oil and wax spar- 
ingly and make sure to wipe off 
any excess. 

• Never apply oil or wax to any 
rubber and plastic parts, but 
treat them with a suitable care 
product. 



7-2 



MOTORCYCLE CARE AND STORAGE 



• Avoid using abrasive polishing 
compounds as they will wear 
away the paint. 

NOTE: 

Consult a Yamaha dealer for advice on 
what products to use. 



Storage 

Short-term 

Always store your motorcycle in a cool, 
dry place and, if necessary, protect it 
against dust with a porous cover. 

ECA10810 

CAUTION: 

• Storing the motorcycle in a 
poorly ventilated room or cover- 
ing it with a tarp, while it is still 
wet, will allow water and humid- 
ity to seep in and cause rust. 

• To prevent corrosion, avoid 
damp cellars, stables (because 
of the presence of ammonia) 
and areas where strong chemi- 
cals are stored. 

Long-term 

Before storing your motorcycle for sev- 
eral months: 

1. Follow all the instructions in the 
"Care" section of this chapter. 

2. For motorcycles equipped with a 
fuel cock that has an "OFF" posi- 
tion: Turn the fuel cock lever to 
"OFF". 

7-3 



Drain the carburetor float cham- 
bers by loosening the drain bolts; 
this will prevent fuel deposits from 
building up. Pour the drained fuel 
into the fuel tank. 

Fill up the fuel tank and add fuel 
stabilizer (if available) to prevent 
the fuel tank from rusting and the 
fuel from deteriorating. 
Perform the following steps to pro- 
tect the cylinders, piston rings, etc. 
from corrosion. 

a. Remove the spark plug caps 
and spark plugs. 
Pour a teaspoonful of engine oil 
into each spark plug bore. 
Install the spark plug caps onto 
the spark plugs, and then place 
the spark plugs on the cylinder 
head so that the electrodes are 
grounded. (This will limit spark- 
ing during the next step.) 
d. Turn the engine over several 
times with the starter. (This will 
coat the cylinder walls with oil.) 
Remove the spark plug caps 
from the spark plugs, and then 
install the spark plugs and the 
spark plug caps. 



b. 



c. 



e. 



MOTORCYCLE CARE AND STORAGE 



A WARNING 



To prevent damage or injury from 
sparking, make sure to ground the 
spark plug electrodes while turning 
the engine over. 

6. Lubricate all control cables and the 
pivoting points of all levers and 
pedals as well as of the side- 
stand/centerstand. 

7. Check and, if necessary, correct 
the tire air pressure, and then lift 
the motorcycle so that both of its 
wheels are off the ground. Alterna- 
tively, turn the wheels a little every 
month in order to prevent the tires 
from becoming degraded in one 
spot. 

8. Cover the muffler outlets with plas- 
tic bags to prevent moisture from 
entering them. 

9. Remove the battery and fully 
charge it. Store it in a cool, dry 
place and charge it once a month. 
Do not store the battery in an ex- 
cessively cold or warm place [less 
than °C (30 °F) or more than 30 



°C (90 °F)]. For more information 
on storing the battery, see page 
6-29. 



NOTE: 

Make any necessary 
storing the motorcycle. 



repairs before 



7-4 



SPECIFICATIONS 



Dimensions: 

Overall length: 

XVS650 2340 mm (92.1 in) 
XVS650A 2450 mm (96.5 in) 
XVS650AT 2450 mm (96.5 in) 

Overall width: 

XVS650 880 mm (34.6 in) 
XVS650A 930 mm (36.6 in) 
XVS650AT 930 mm (36.6 in) 

Overall height: 

XVS650 1070 mm (42.1 in) 
XVS650A 1 105 mm (43.5 in) 
XVS650AT 1 105 mm (43.5 in) 

Seat height: 

XVS650 695 mm (27.4 in) 
XVS650A 710 mm (28.0 in) 
XVS650AT 710 mm (28.0 in) 

Wheelbase: 

XVS650 1610mm(63.4in) 
XVS650A 1625 mm (64.0 in) 
XVS650AT 1625 mm (64.0 in) 

Ground clearance: 
140 mm (5.51 in) 

Minimum turning radius: 

XVS650 3100 mm (122.0 in) 
XVS650A 3400 mm (133.9 in) 
XVS650AT 3400 mm (133.9 in) 
Weight: 

With oil and fuel: 

XVS650 233.0 kg (514 lb) (U49) 
XVS650 235.0 kg (518 lb) (CAL) 
XVS650A 247.0 kg (545 lb) (U49) 



XVS650A 249.0 kg (549 lb) (CAL) 

XVS650AT 247.0 kg (545 lb) (U49) 

XVS650AT 249.0 kg (549 lb) (CAL) 
Engine: 
Engine type: 

Air cooled 4-stroke, SOHC 
Cylinder arrangement: 

V-type 2-cylinder 
Displacement: 

649.0 cm 3 (39.60 cu.in) 
Bore x stroke: 

81 .0 x 63.0 mm (3.19 x 2.48 in) 
Compression ratio: 

9.00 :1 
Starting system: 

Electric starter 
Lubrication system: 

Wet sump 
Engine oil: 
Type: 

YAMALUBE 4, SAE10W30 or SAE20W40 



0° 10° 30° 50° 70° 90° 110°130°F 
I I I I I I I 
) 1 1 1 *. 

YAMALUBE 4 (10W30) 
orSAE10W30 



YAMALUBE 4 (20W40) 
or SAE 20W40 



-20° -10° 0° 10° 20° 30° 40° 50°C 



Recommended engine oil grade: 

API service SE, SF, SG type or higher 

8-1 



Engine oil quantity: 

Without oil filter element replacement: 

2.60 L (2.75 US qt) (2.29 Imp.qt) 
With oil filter element replacement: 
2.80 L (2.96 US qt) (2.46 Imp.qt) 
Final gear oil: 
Type: 

SAE80 API GL-4 Hypoid gear oil 
Quantity: 

0.19 L (0.20 US qt) (0.17 Imp.qt) 
Air filter: 

Air filter element: 
Dry element 
Fuel: 

Recommended fuel: 

Unleaded gasoline only 
Fuel tank capacity: 

16.0 L (4.23 US gal) (3.52 Imp.gal) 
Fuel reserve amount: 

3.0 L (0.79 US gal) (0.66 Imp.gal) 
Carburetor: 
Manufacturer: 

MIKUNI 
Type x quantity: 
BDS28 x 2 
Spark plug(s): 
Manufacturer/model: 
NGK/DPR7EA-9 
Manufacturer/model: 

DENSO/X22EPR-U9 
Spark plug gap: 

0.8-0.9 mm (0.031-0.035 in) 



SPECIFICATIONS 



Clutch: 

Clutch type: 

Wet, multiple-disc 
Transmission: 

Primary reduction system: 

Spur gear 
Primary reduction ratio: 

68/38 (1 .789) 
Secondary reduction system: 

Shaft drive 
Secondary reduction ratio: 

19/18x32/11 (3.071) 
Transmission type: 

Constant mesh 5-speed 
Operation: 

Left foot operation 
Gear ratio: 
1st: 

38/14(2.714) 
2nd: 

38/20(1.900) 
3rd: 

35/24(1.458) 
4th: 

28/24(1.167) 
5th: 

29/30 (0.967) 
Chassis: 
Frame type: 

Double cradle 
Caster angle: 
35.00 ° 



Trail: 

XVS650 153.0 mm (6.02 in) 

XVS650A 145.0 mm (5.71 in) 

XVS650AT 145.0 mm (5.71 in) 
Front tire: 
Type: 

With tube 
Size: 

XVS650 1 00/90-1 9M/C 57S 

XVS650A 1 30/90-1 6M/C 67S 

XVS650AT 1 30/90-1 6M/C 67S 
Manufacturer/model: 

XVS650 BRIDGESTONE/EXEDRA L309 

XVS650A BRIDGESTONE/EXEDRA 

G703 

XVS650AT BRIDGESTONE/EXEDRA 

G703 
Manufacturer/model: 

XVS650 DUNLOP/F24 

XVS650A DUNLOP/D404F 

XVS650AT DUNLOP/D404F 
Rear tire: 
Type: 

With tube 
Size: 

1 70/80-1 5M/C77S 
Manufacturer/model: 

XVS650 BRIDGESTONE/EXEDRA G546 

XVS650A BRIDGESTONE/EXEDRA 

G702 

XVS650AT BRIDGESTONE/EXEDRA 

G702 



Manufacturer/model: 
XVS650 DUNLOP/K555 
XVS650A DUNLOP/D404G 
XVS650AT DUNLOP/D404G 
Loading: 

Maximum load: 

XVS650 178 kg (392 lb) (CAL) 
XVS650 180 kg (397 lb) (U49) 
XVS650A 198 kg (437 lb) (CAL) 
XVS650A 200 kg (441 lb) (U49) 
XVS650AT 198 kg (437 lb) (CAL) 
XVS650AT 200 kg (441 lb) (U49) 
(Total weight of rider, passenger, cargo and 
accessories) 
Tire air pressure (measured on cold 
tires): 

Loading condition: 
0-90 kg (0-198 lb) 
Front: 

XVS650 200 kPa (29 psi) (2.00 kgf/cm 2 ) 
XVS650A 225 kPa (33 psi) (2.25 
kgf/cm 2 ) 

XVS650AT 225 kPa (33 psi) (2.25 
kgf/cm 2 ) 
Rear: 

225 kPa (33 psi) (2.25 kgf/cm 2 ) 
Loading condition: 

XVS650 90-178 kg (198-392 lb) (CAL) 
XVS650 90-180 kg (198-397 lb) (U49) 
XVS650A 90-198 kg (198-437 lb) (CAL) 
XVS650A 90-200 kg (198-441 lb) (U49) 
XVS650AT 90-198 kg (198-437 lb) (CAL) 
XVS650AT 90-200 kg (198-441 lb) (U49) 



8-2 



SPECIFICATIONS 



Front: 

XVS650 200 kPa (29 psi) (2.00 kgf/cm 2 ) 
XVS650A 225 kPa (33 psi) (2.25 
kgf/cm 2 ) 

XVS650AT 225 kPa (33 psi) (2.25 
kgf/cm 2 ) 
Rear: 

250 kPa (36 psi) (2.50 kgf/cm 2 ) 
Front wheel: 
Wheel type: 

Spoke wheel 
Rim size: 

XVS650 19M/CxMT2.50 
XVS650A 16M/C x MT3.00 
XVS650AT 16M/C x MT3.00 
Rear wheel: 
Wheel type: 

Spoke wheel 
Rim size: 

15M/CxMT3.50 
Front brake: 
Type: 

Single disc brake 
Operation: 

Right hand operation 
Recommended fluid: 
DOT 4 
Rear brake: 
Type: 

Drum brake 
Operation: 

Right foot operation 



Front suspension: 

Type: 

Telescopic fork 
Spring/shock absorber type: 

Coil spring/oil damper 
Wheel travel: 

140.0 mm (5.51 in) 
Rear suspension: 
Type: 

Swingarm (monocross) 
Spring/shock absorber type: 

Coil spring/gas-oil damper 
Wheel travel: 

XVS650 86.0 mm (3.39 in) 

XVS650A 98.0 mm (3.86 in) 

XVS650AT 98.0 mm (3.86 in) 
Electrical system: 
Ignition system: 

Transistorized coil ignition (digital) 
Charging system: 

A.C. magneto 
Battery: 
Model: 

GT12B-4 
Voltage, capacity: 

12 V, 10.0 Ah 
Headlight: 
Bulb type: 

Halogen bulb 
Bulb voltage, wattage x quantity: 
Headlight: 

12 V, 60W/55.0Wx1 
Tail/brake light: 

12 V, 8.0/27.0 Wx1 



Front turn signal/position light: 

XVS650 1 2 V, 27 W/8.0 W x 2 

XVS650A 12 V, 23 W/8.0 W x 2 

XVS650AT 1 2 V, 23 W/8.0 W x 2 
Rear turn signal light: 

XVS650 12 V, 27.0 Wx2 

XVS650A12 V, 21.0 Wx2 

XVS650AT 1 2 V, 21 .0 W x 2 
Meter lighting: 

12 V, 1.7 Wx1 
Neutral indicator light: 

12 V, 1.7 Wx1 
High beam indicator light: 

12 V, 1.7 Wx1 
Turn signal indicator light: 

12 V, 1.7 Wx1 
Engine trouble warning light: 

12 V, 1.7 Wx1 
Fuses: 
Main fuse: 

30.0 A 
Headlight fuse: 

15.0A 
Signaling system fuse: 

10.0A 
Ignition fuse: 

10.0A 
Carburetor heater fuse: 

15.0A 
Ignitor unit fuse: 

XVS650 5.0 A (CAL) 

XVS650A 5.0 A (CAL) 

XVS650AT 5.0 A (CAL) 



8-3 



CONSUMER INFORMATION 



Identification numbers 

Record the key identification number, 
vehicle identification number and mod- 
el label information in the spaces pro- 
vided below for assistance when 
ordering spare parts from a Yamaha 
dealer or for reference in case the vehi- 
cle is stolen. 
KEY IDENTIFICATION NUMBER: 



Key identification number 



VEHICLE IDENTIFICATION 
NUMBER: 



MODEL LABEL INFORMATION: 





1. Key identification number 

The key identification number is 
stamped into the key tag. Record this 
number in the space provided and use 
it for reference when ordering a new 
key. 



Vehicle identification number 




Vehicle identification number 



The vehicle identification number is 
stamped into the steering head pipe. 
Record this number in the space pro- 
vided. 

NOTE: 

The vehicle 



identification number is 
used to identify your motorcycle and 
may be used to register your motor- 
cycle with the licensing authority in your 
area. 



9-1 



CONSUMER INFORMATION 



Model label 




1. Model label 

The model label is affixed to the frame 
under the rider seat. (See page 3-9.) 
Record the information on this label in 
the space provided. This information 
will be needed when ordering spare 
parts from a Yamaha dealer. 



9-2 



CONSUMER INFORMATION 



Reporting safety defects 

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately 
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, 
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group 
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems 
between you, your dealer, or Yamaha Motor Corporation, U.S.A. 

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1 -800-424-9393 (or 366-01 23 in Washington, D.C. 
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information 
about motor vehicle safety from the Hotline. 



9-3 



CONSUMER INFORMATION 



Motorcycle noise regulation 

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: 

Federal law prohibits the following acts or the causing thereof: (1 ) The removal or rendering inoperative by any person other 
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- 
hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of 
the vehicle after such device or element of design has been removed or rendered inoperative by any person. 
"AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW". 
These acts include tampering with the following systems; i.e., modification, removal, etc. 



Exhaust system 

• Muffler 

• Exhaust pipe 

• Silencer 
Intake system 

• Air cleaner case 

• Air cleaner element 

• Intake duct 



9-4 



CONSUMER INFORMATION 



Maintenance record 

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that 
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder 
that maintenance work is required. It is not acceptable proof of maintenance work. 



Maintenance 
interval 


Date of 
service 


Mileage 


Servicing dealer 
name and address 


Remarks 


600 mi 

(1000 km) or 

1 month 










4000 mi 

(7000 km) or 

6 months 










8000 mi 

(13000 km) or 

12 months 










12000 mi 

(19000 km) or 

18 months 










16000 mi 

(25000 km) or 

24 months 










20000 mi 

(31000 km) or 

30 months 










24000 mi 

(37000 km) or 

36 months 










28000 mi 

(43000 km) or 

42 months 










32000 mi 

(49000 km) or 

48 months 











9-5 



CONSUMER INFORMATION 



Maintenance 
interval 


Date of 
service 


Mileage 


Servicing dealer 
name and address 


Remarks 


36000 mi 

(55000 km) or 

54 months 










40000 mi 

(61000 km) or 

60 months 











9-6 



CONSUMER INFORMATION 



YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED 
WARRANTY 



Yamaha Motor Corporation, U.S.A. hereby warrants 
each new model Yamaha motorcycle will be free from 
defects in material and workmanship for the period of 
time stated herein, subject to certain stated limitations. 

THE PERIOD OF WARRANTY for Yamaha motorcycles 
originally equipped with headlight, stoplight, and turn 
signals shall be one (1 ) year from the date of purchase, 

with no mileage limitation. 

MODELS EXCLUDED FROM WARRANTY include 
those used for non-Yamaha-authorized renting, leas- 
ing, or other commercial purposes, and TZ models. 

DURING THE PERIOD OF WARRANTY any authorized 
Yamaha motorcycle dealer will, free of charge, repair 
or replace any part adjudged defective by Yamaha due 
to faulty workmanship or material from the factory. 

Parts used in warranty repairs will be warranted for 
the balance of the product's warranty period. All parts 
replaced under warranty become property of Yamaha 
Motor Corp. U.S.A. 

GENERAL EXCLUSIONS from this warranty shall 
include any failures caused by: 

a. Competition or racing use. 

b. Installation of parts or accessories that are not 
qualitatively equivalent to genuine Yamaha parts. 

c. Abnormal strain, neglect, or abuse. 

d. Lack of proper maintenance. 

e. Accident or collision damage. 

f. Modification to original parts. 

SPECIFIC EXCLUSIONS from this warranty shall 
include parts replaced due to normal wear or routine 
maintenance. 



THE CUSTOMER'S RESPONSIBILITY under this war- 
ranty shall be to: 

1 . Operate and maintain the motorcycle as specified 
in the appropriate Owner's Manual, and 

2. Give notice to an authorized Yamaha motorcycle 
dealer of any and all apparent defects within ten 
(10) days after discovery, and make the machine 
available at that time for inspection and repairs at 
such dealer's place of business. 

WARRANTY TRANSFER: To transfer the warranty 
from the original purchaser to any subsequent pur- 
chaser, it is imperative that the machine be inspected 
and registered for warranty by an authorized Yamaha 
motorcycle dealer. In order for this warranty to remain 
in effect, this inspection and registration must take 
place within ten (10) days after transfer. An inspection and 
registration fee will be charged for this service. 

EMISSIONS CONTROL SYSTEM WARRANTY 

Yamaha Motor Corporation, U.S.A. also warrants to the 
ultimate purchaser and each subsequent purchaser of 
each Yamaha motorcycle covered by this warranty 
with a displacement of 50cc or greater, that the vehi- 
cle is designed, built, and equipped so as to conform 
at the time of sale with all U.S. emissions standards 
applicable at the time of manufacture and that it is free 
from defects in materials and workmanship which 
would cause it not to meet these standards within the 
periods listed immediately below. Failure other than 
those resulting from defects in material or workman- 
ship which arise solely as a result of owner abuse 
and / or lack of proper maintenance are not covered by 
this warranty. 



ENGINE 
DISPLACEMENT 

50cc to 169cc 



PERIOD 

12,000 km (7,465 miles) 
or five years, whichever occurs first 



170ccto279cc 18,000 km (11,185 miles) 

or five years, whichever occurs first 

280cc or over 30,000 km (18,641 miles) 

or five years, whichever occurs first 

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 
OTHER WARRANTY OF ANY KIND, EXPRESSED OR 
IMPLIED. ALL IMPLIED WARRANTIES OF MER- 
CHANTABILITY AND FITNESS FOR A PARTICULAR 
PURPOSE WHICH EXCEED THE OBLIGATIONS AND 
TIME LIMITS STATED IN THIS WARRANTY ARE 
HEREBY DISCLAIMED BY YAMAHA MOTOR COR- 
PORATION, U.S.A. AND EXCLUDED FROM THIS 
WARRANTY. 

SOME STATES DO NOT ALLOW LIMITATIONS ON 
HOW LONG AN IMPLIED WARRANTY LASTS, SO THE 
ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO 
EXCLUDED FROM THIS WARRANTY ARE ANY IN- 
CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD- 
ING LOSS OF USE. SOME STATES DO NOT ALLOW 
THE EXCL USION OR LIMIT A TION OF INCIDENTAL OR 
CONSEQUENTIAL DAMAGES, SO THE ABOVE 
EXCLUSION MAY NOT APPLY TO YOU. 

THIS WARRANTY GIVES YOU SPECIFIC LEGAL 
RIGHTS, AND YOU MA Y ALSO HA VE OTHER RIGHTS 
WHICH VARY FROM STATE TO STATE. 

YAMAHA MOTOR CORPORATION, U.S.A. 

P.O. Box 6555 

Cypress, California 90630 



9-7 



CONSUMER INFORMATION 



WARRANTY QUESTIONS AND ANSWERS 



CUSTOMER SERVICE 



Q. What costs are my responsibility during the warranty period? 

A. The customer's responsibility includes all costs of normal maintenance services, non- 
warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark 
plugs, and brake shoes. 

Q. What are some examples of "abnormal" strain, neglect, or abuse? 

A. These terms are general and overlap each other in areas. Specific examples include: 
Running the machine out of oil, sustained high-rpm, full-throttle, operating the 
machine with a broken or damaged part which causes another part to fail, damage 
or failure due to improper or careless transportation and or tie down. If you have any 
specific questions on operation or maintenance, please contact yourdealerfor advice. 

Q. Does the warranty cover incidental costs such as towing or transportation due to 

a failure? 
A. No. The warranty is limited to repair of the machine itself. 

Q. May I perform any or all of the recommended maintenance shown in the.Owner's 

Manual instead of having the dealer do them? 
A. Yes, if you area qualified mechanic and follow the procedures specified in the Owner's 

and Service Manual. We do recommend, however, that items requiring special tools 

or equipment be done by Yamaha Motorcycle dealer. 

Q. Will the warranty be void or cancelled if I do not operate or maintain my new motor- 
cycle exactly as specified in the Owner's Manual? 

A. No. The warranty on a new motorcycle cannot be "voided" or "cancelled." However, 
if a particular failure is caused by operation or maintenance other than as shown 
in the Owner's Manual, that failure may not be covered under warranty. 

Q. What responsibility does my dealer have under this warranty? 
A. Each Yamaha Motorcycle dealer is expected to: 

1 . Completely set up every new machine before sale. 

2. Explain the operation, maintenance, and warranty requirements to your satis- 
faction at the time of sale, and upon your request at any later date. 

3. Each Yamaha Motorcycle dealer is held responsible for his setup, service and 
warranty repair work. 

Q. Is the warranty transferable to second owners? 

A. Yes. The remainder of the existing warranty can be transferred upon request. The 

unit has to be inspected and re-registered by an authorized Yamaha Motorcycle dealer 

for the policy to remain effective. 



If your machine requires warranty service, you must take it to any authorized 
Yamaha Motorcycle dealer within the continental United States. Be sure to 
bring your warranty registration card or other valid proof of the original date 
of purchase. If a question or problem arises regarding warranty, first con- 
tact the owner of the dealership. Since all warranty matters are handled at 
the dealer level, this person is in the best position to help you. If you are 
still not satisfied and require additional assistance, please write: 

YAMAHA MOTOR CORPORATION U.S.A. 

CUSTOMER RELATIONS DEPARTMENT 

P.O. Box 6555 

Cypress, California 90630 

When contacting Yamaha Motor Corporation, U.S.A. don't forget to include 
any important information such as names, addresses, model, V.I.N, (frame 
number), dates, and receipts. 

CHANGE OF ADDRESS 

The federal government requires each manufacturer of a motor vehicle to 
maintain a complete, up-to-date list of all first purchasers against the 
possibility of a safety-related defect and recall. This list is compiled from 
the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the 
selling dealer at the time of your purchase. 

If you should move after you have purchased your new motorcycle, please 
advise us of your new address by sending a postcard listing your motorcycle 
model name, V.I.N, (frame number), dealer number (or dealer's name) as it 
is shown on your warranty card, your name and new mailing address. Mail to: 

YAMAHA MOTOR CORPORATION, U.S.A. 

P.O. Box 6555 

Cypress, California 90630 

Attention: Warranty Department 

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date 
registration record in accordance with federal law. 



9-8 



CONSUMER INFORMATION 



YAMAHA EXTENDED SERVICE (Y.E.S.) 

Keep your Yamaha protected even after your warranty 
expires with genuine Yamaha Extended Service (Y.E.S.). 

• Y.E.S. is designed and administered by Yamaha Motor 
Corporation to provide maximum owner satisfaction. You 
get uninterrupted factory-backed coverage for extra 
peace of mind. 

• Y.E.S. is flexible. You choose the plan that's right for 
you: 12 months, 24 months, 36 months or, on certain 
models, even 48 months beyond your warranty period. 

• Y.E.S. is designed and administered by the same 
Yamaha people who handle your warranty - and it 
shows in the comprehensive coverage benefits. There 
are no mileage limitations. Coverage isn't limited to 
"moving parts" or the "drive train" like many other plans. 
And Y.E.S. covers manufacturing defects just like the 
warranty. See the sample contract at your Yamaha 
dealer to see how comforting uninterrupted factory- 
backed protection can be. 

• You don't have to pay anything for covered repairs. 
There's no deductible to pay, and repairs aren't 
"pro-rated." You don't have any "out-of-pocket" expenses 
for covered repairs. 



• In addition, Travel and Recreation Interruption Protection 
(TRIP) is included at no extra cost. TRIP gives you up to 
$150 reimbursement per occurrence for any reasonable 
expenses you incur because your Yamaha needs 
covered service: replacement vehicle rental, emergency 
towing, phone calls, even food and lodging when you are 
away from home. This superb coverage goes into effect 
when you purchase Y.E.S., so it applies to any warranty 
repairs as well as covered repairs during your entire 
Y.E.S. plan period. 

• Y.E.S. coverage is honored at any authorized Yamaha 
dealer nationwide. 

• Y.E.S. coverage is transferable to a new owner if you 
sell or trade-in. That can make your Yamaha much more 
valuable! 

This excellent Y.E.S. plan coverage is only available to 
Yamaha owners like you, and only while your Yamaha is still 
within the Yamaha Limited Warranty period. So visit your 
authorized Yamaha dealer to get all the facts. He can show 
you how easy it is to protect your investment with Yamaha 
Extended Service. 



9-9 



CONSUMER INFORMATION 



We urge you to act now. You'll get the excellent benefits of 
TRIP coverage right away, and you'll rest easy knowing 
you'll have strong factory-backed protection even after your 
Yamaha Limited Warranty expires. 

A special note: 

If visiting your dealer isn't convenient, contact Yamaha with 
your Primary ID number (your frame number). We'll be 
happy to help you get the Y.E.S. coverage you need. 

Yamaha Service Marketing 

P.O. Box 6555 

Cypress, CA 90630 

1 -(866)-YES-EXTD (1 -866-937-3983) 




YAMAHA EXTENDED SERVICE 



9-10 



INDEX 



A 

Accessories and replacement parts 6-19 

Airfilter element, cleaning 6-14 

B 

Battery 6-29 

Brake and clutch levers, 

checking and lubricating 6-26 

Brake and shift pedals, 

checking and lubricating 6-26 

Brake fluid, changing 6-25 

Brake fluid level, checking 6-24 

Brake lever 3-5 

Brake lever free play, adjusting 6-21 

Brake pads and shoes, checking 6-24 

Brake pedal 3-5 

Brake pedal position and free play, 
adjusting 6-22 

C 

Cables, checking and lubricating 6-25 

Canister (for California only) 6-10 

Carburetors, adjustment 6-16 

Care 7-1 

Catalytic converter 3-7 

Clutch lever 3-4 

Clutch lever free play, adjusting 6-20 

D 
Dimmer switch 3-3 

E 

Engine break-in 5-4 

Engine oil and oil filter element 6-1 1 

Engine, starting a warm 5-2 

Engine stop switch 3-3 

Engine trouble warning light 3-2 



F 

Final gear oil 6-13 

Front fork, checking 6-27 

Fuel 3-6 

Fuel cock 3-7 

Fuel tank cap 3-5 

Fuses, replacing 6-30 

H 

Handlebar switches 3-3 

Headlight bulb, replacing 6-31 

Helmet holder 3-11 

High beam indicator light 3-2 

Horn switch 3-3 

I 

Identification numbers 9-1 

Ignition circuit cut-off system 3-14 

Indicator and warning lights 3-2 

K 
Key identification number 9-1 

L 

Labels, location of 1-5 

Luggage strap holders 3-13 

M 

Main switch/steering lock 3-1 

Maintenance and lubrication, periodic 6-4 

Maintenance, emission control system ...6-3 

Maintenance, periodic 6-1 

Maintenance record 9-5 

Model label 9-2 

N 

Neutral indicator light 3-2 

Noise regulation 9-4 

P 
Panels, removing and installing 6-8 



Parking 5-5 

Part locations 2-1 

Pre-operation check list 4-2 

R 
Rear brake light switch, adjusting 6-23 

S 

Safety defects, reporting 9-3 

Safety information 1-1 

Seats (XVS650) 3-9 

Seats (XVS650A/AT) 3-10 

Shifting 5-3 

Shift pedal (XVS650) 3-4 

Shift pedal (XVS650A/AT) 3-4 

Shock absorber assembly, adjusting.... 3-12 

Sidestand 3-13 

Sidestand, checking and lubricating 6-27 

Spark plugs, checking 6-9 

Specifications 8-1 

Speedometer unit 3-2 

Starter (choke) knob 3-8 

Starting and warming up a cold 

engine 5-1 

Start switch 3-3 

Steering, checking 6-28 

Storage 7-3 

Storage compartment 3-1 1 

Supporting the motorcycle 6-33 

T 

Throttle cable free play, adjusting 6-16 

Throttle grip and cable, 

checking and lubricating 6-26 

Tires 6-17 

Tool kit 6-1 

Troubleshooting 6-37 



INDEX 



Troubleshooting chart 6-38 

Turn signal indicator light 3-2 

Turn signal light bulb or 

tail/brake light bulb, replacing 6-32 

Turn signal switch 3-3 

V 

Valve clearance, adjusting 6-16 

Vehicle identification number 9-1 

W 

Warranty, extended 9-9 

Warranty, limited 9-7 

Wheel bearings, checking 6-28 

Wheel (front) 6-34 

Wheel (rear) 6-35 

Wheels 6-19 



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YAMAHA MOTOR CO., LTD. 

PRINTED IN JAPAN 

2004.05-2.6x1 CR 

(E)